A vibration-based ladle nozzle refractory repair device, system, and method

Abstract

The application discloses a ladle mouth refractory repairing device, system and method based on vibration, and belongs to the technical field of converter steelmaking. The repairing device comprises a maintenance platform, a circular guide rail, a maintenance trolley, a repairing material spray irrigation system, a vibration system and a control system. A pouring mold plate is used to form a pouring chamber with the inner wall of the ladle. The pouring chamber has a front side in the running direction of the maintenance trolley, and the space of the front side is larger than that of the rear side. The vibration system is arranged on the pouring mold plate and used for vibrating the repairing material in the pouring chamber. During the spraying and repairing process, the repairing material is subjected to continuous "vibration liquefaction" and "dynamic mechanical extrusion" double actions. This can effectively discharge the bubbles in the slurry, force the particles to rearrange and greatly reduce the porosity. The continuous movement of the device along the preset circular track for repairing is combined with the hot self-sintering realized by the residual heat of the ladle, so that the repairing material is seamlessly connected and uniformly solidified in the annular area.

Description

Technical Field

[0001] This invention relates to the field of steelmaking technology, specifically to the maintenance of ladle openings and the repair of refractory materials, and provides a vibration-based ladle opening refractory material repair device, system, and method. Background Technology

[0002] The ladle is a crucial container for carrying molten steel. Its slag line and ladle opening area are the most vulnerable parts due to long-term exposure to high-temperature slag chemical erosion, mechanical scouring by molten steel, and severe thermal shock. If cracks, spalling, or abnormal slag adhesion appear at the ladle opening, it will lead to the oxidation of exposed brick plates, interference with refining equipment, and in severe cases, leakage accidents, forcing the ladle to be taken off the production line for maintenance prematurely, affecting production rhythm and safety.

[0003] The mainstream technologies for repairing ladle openings currently involve manual spraying with a gun or semi-automatic spraying machines. During operation, refractory material is sprayed onto the damaged surface, and the residual heat of the ladle or a flame is used to sinter and solidify it. In recent years, mobile circumferential spraying devices have emerged in the industry, enabling continuous operation along the circumference of the ladle opening. Meanwhile, ladle hot repair systems are developing towards integration and unmanned operation (such as industry standard YB / T6168-2024), but mainly focus on auxiliary functions such as tilting, nozzle replacement, and dust removal.

[0004] Analysis reveals that existing spray patching technology and equipment still have the following prominent shortcomings when applied to repairing bag seams: (1) Poor compactness of the repair layer: Existing technology only solves the problem of material "adhesion". The sprayed layer is in a piled state with high porosity and loose structure. Its strength and erosion resistance are far lower than the original brick lining, resulting in a short service life of the repair layer and becoming a new weak link. There is a lack of active means to carry out effective mechanical compaction at the same time during the spraying process.

[0005] (2) Poor uniformity of ring repair: The opening is a ring-shaped curved surface. Simple moving spraying is difficult to ensure uniform thickness, tight interlayer bonding and seamless connection on the circumference. It is easy to produce quality defects such as uneven thickness and obvious joints, which affect the overall sealing performance.

[0006] (3) Insufficient adaptability of process parameters: The erosion shape of the pot mouth varies from furnace to furnace, while the existing automated equipment mostly adopts fixed program operation, which cannot dynamically adjust the spraying amount, speed and compaction parameters according to the real-time erosion contour, which easily leads to waste due to over-padding of shallow pits and under-padding of deep trenches, leaving hidden dangers.

[0007] (4) Limited level of automation and intelligence: Although robotic arms have replaced manual spraying, there is a lack of a closed-loop control system that integrates real-time three-dimensional scanning, intelligent path planning, parameter adaptive adjustment and online quality assessment. Repair quality still depends on human experience and has not achieved precise control.

[0008] (5) Occupational safety risks have not been fundamentally eliminated: Repair work still requires workers to approach the high-temperature steel ladle for operation and observation, which poses risks of high-temperature radiation, dust and mechanical injury, and has not achieved remote unmanned operation. Summary of the Invention

[0009] To address the aforementioned shortcomings, this invention aims to provide a vibration-based refractory repair device, system, and method for ladle rim repair. This invention utilizes a casting template and the inner wall of the ladle to form a casting chamber. The casting chamber's front side is larger than its rear side, with the repair trolley's running direction as the front side. A vibration system is installed on the casting template to vibrate the repair material within the casting chamber. By introducing an integrated vibration compaction system and a conical leading dynamic extrusion structure during the spraying process, active densification and compaction of the sprayed material are achieved. Combined with intelligent detection and adaptive control, this improves the density, uniformity, and bonding strength of the repair layer, while reducing manual intervention and enhancing operational safety and efficiency.

[0010] The innovative concept of this invention is to design and invent a special device for repairing the refractory material at the ladle opening, enabling timely maintenance and efficient repair of this area and extending the ladle's service life. After the ladle is poured in the continuous casting machine, the slag inside is emptied, and the ladle is hoisted to a ladle maintenance platform. The repair device is then activated to spray and pour repair material, moving along a fixed, dedicated circular guide rail to perform the repair. This achieves efficient repair and maintenance of the ladle opening, reducing labor intensity and process costs, avoiding safety and equipment hazards, and ensuring safe, stable, and smooth production. This innovative concept is simple, efficient, safe, and practical, with significant economic and social benefits and broad application prospects.

[0011] The technical problem to be solved by the present invention is achieved by the following technical solution: a vibration-based refractory repair device for steel ladle openings, comprising a repair platform, a circular guide rail, a repair trolley, a repair material spraying system, a vibration system, and a control system; The maintenance platform has a ladle placement area in the middle, and the circular guide rail is set on the maintenance platform and located outside the ladle placement area. The maintenance trolley includes a trolley body, a trolley motion drive mechanism, a lifting bracket, a cantilever beam, and a casting template. The trolley body is positioned above a circular guide rail. The trolley motion drive mechanism and the lifting bracket are mounted on the trolley body. The cantilever beam is laterally positioned at the upper end of the lifting bracket. The casting template is positioned at the end of the cantilever beam. The casting template is used to form a casting chamber with the inner wall of the ladle. The casting chamber has a front side with the direction of operation of the maintenance trolley as the front side, and its front space is larger than its rear space. The repair material spraying system is installed on the trolley body and is used to inject repair material into the pouring chamber; The vibration system is installed on the casting template and is used to vibrate the repair material in the casting cavity; The control system is connected to the trolley motion drive mechanism, lifting support, repair material spraying system, and vibration system.

[0012] Preferably, the present invention further includes a positioning system, which includes a positioning beam, a telescopic rod, a spring, and rollers; The positioning beam is horizontally arranged on the trolley body; The positioning beam is provided with a sliding groove at its end, and the telescopic rod is slidably disposed in the sliding groove. One end of the telescopic rod is connected to the inner wall of the sliding groove by a spring, and the roller is rotatably disposed at the other end of the telescopic rod. The positioning beam is located between the ladle shell and the trolley support column. The end of the positioning beam near the ladle shell is equipped with springs and rollers to ensure a seamless pouring of the vertical plate and the inner surface of the ladle refractory material. The positioning system provides auxiliary support, ensuring the stable operation of the pouring template and the maintenance trolley during maintenance.

[0013] Preferably, the casting template of the present invention includes a casting upright plate and a casting cover plate, wherein the casting upright plate is vertically arranged below the cantilever beam, and the casting cover plate is horizontally arranged on the casting upright plate; The cross-sections of the casting plate and the side wall of the ladle opening, and the cross-sections of the casting cover plate and the ladle opening, are respectively set at acute angles.

[0014] Preferably, the repair material spraying system of the present invention includes a spray gun nozzle, a spray metal pipe, a spray hose, a material tank, a control valve, and a compressed gas supply system; The spray gun nozzle is inserted into the casting cover plate and communicates with the casting chamber; The spray gun nozzle is connected in sequence to the spray metal pipe, the spray hose, and the material tank. The spray hose is equipped with a control valve, and the spray metal pipe is fixed on the cantilever beam. The material tank is connected to a compressed gas supply system. The metal spray pipe is used to withstand the high temperature inside the ladle, and the flexible spray hose is used to meet the lifting requirements of the lifting support.

[0015] Preferably, the vibration system of this invention includes at least one variable frequency vibration motor, which is located at the angle between the casting slab and the casting cover plate. The variable frequency vibration motor is fixed at the angle between the casting slab and the casting cover plate, simultaneously vibrating both the casting slab and the casting cover plate. The casting slab and the casting cover plate serve as a "vibration template" for indirect transmission.

[0016] Preferably, the vibration system of the present invention includes two variable frequency vibration motors, which are asymmetrically arranged on both sides of the casting chamber to generate composite micro-vibration, which is more conducive to the discharge of air bubbles and the compaction of slurry.

[0017] Preferably, the base circle radius of the circular guide rail and the working surface curvature radius of the casting plate are both matched with the designed curvature radius of the inner lining of the target ladle.

[0018] The present invention also discloses a vibration-based refractory repair system for ladle openings, including the vibration-based refractory repair device for ladle openings described above, and further including a detection system; The detection system includes a laser scanner and an infrared temperature measuring device positioned above the ladle. The laser scanner is used to acquire the erosion morphology of the ladle and generate a three-dimensional model of the erosion profile. The infrared temperature measuring device is used to collect the real-time temperature of the casting template. The control system calculates the erosion depth and relative area based on the morphology of the eroded area, and determines the corresponding repair parameters based on the self-built database. The corresponding repair parameters include the amount of repair material, the vibration frequency of the vibration system, and the sintering time. The self-built database contains different repair parameters corresponding to different erosion morphologies, which are obtained by collecting data from laser scanners, infrared thermometers, and historical data of repair parameters.

[0019] Before repair begins, the laser scanner rapidly scans the inner lining of the bag opening, generating a 3D model of the erosion profile, calculating the volume requiring repair, and automatically planning the amount of spray material. Based on a database matching repair material parameters with process parameters, the system optimizes the process parameters, automatically selecting and applying parameters such as vibration frequency, spray pressure, and static sintering time (optimized based on historical database data and big data calculations; different erosion morphologies in the database correspond to different relevant parameters; based on the current morphology detection results, the model automatically selects the optimal parameters for the current morphology), achieving "intelligent and precise repair."

[0020] The optimal process parameters are calculated based on the morphology of the eroded area. Different erosion depths and relative areas correspond to different amounts of repair material. Different erosion depths also correspond to different vibration frequencies and sintering times. The greater the erosion depth and the larger the area of ​​the repaired area, the more repair material is required, the longer the spraying time, the longer the sintering time, and the slower the maintenance trolley moves.

[0021] The spraying pressure is the pressure of the gas supplied inside the spray gun, ensuring that the mixture of repair material and water is sprayed out to prevent clogging. When the erosion depth is small and thin, the pressure should be increased appropriately to ensure that the repair material is sprayed to the bottom.

[0022] Preferably, the present invention also includes a user interface; The user interface is used to input setting parameters, display device status, and alarm information; The control system interlocks the trolley motion drive mechanism, the lifting bracket, and the repair material spraying system. If the lifting bracket is not in position, the trolley motion drive mechanism is prohibited from operating, and the repair material spraying system will suspend spraying if the pressure is insufficient.

[0023] This invention also discloses a vibration-based method for repairing refractory material at the mouth of a steel ladle, including the aforementioned vibration-based refractory material repair system for the mouth of a steel ladle, comprising the following steps: S1. Determine whether ladle repair is necessary based on the ladle corrosion and production schedule; S2. When ladle repair is required, after the ladle has been poured in the continuous casting machine, the overhead crane will be used to remove the remaining steel slag from the ladle. S3. Hoist the ladle to the ladle placement area on the maintenance platform, with the ladle opening facing vertically upwards; S4. Start the lifting support, raise the casting template, move the repair trolley to the repair position, and then lower the casting template. The casting template and the inner wall of the ladle form a casting chamber. S5. Start the repair material spraying system and inject repair material into the pouring chamber (the "repair chamber" enclosed by the pouring slab, the pouring cover plate and the old lining) for pouring repair; the amount of spraying material used depends on the condition of the eroded part to be repaired.

[0024] At the same time, the vibration system is activated to compact the repair material to ensure that the refractory is compacted without air bubbles; S6. Precise control of process detection and feedback in the "sprinkler-vibration-sintering-movement" sequence: A non-contact infrared thermometer is used to monitor the temperature of the casting template in real time. The control system controls the sintering completion time based on the temperature of the casting template. That is, the control system automatically determines the completion of sintering through a preset delay program. The delay program is optimized by the model, and different erosion morphologies correspond to different amounts of repair material and sintering times (i.e., the preset delay after repair). At the same time, the sintering effect can be indirectly reflected by the temperature of the casting cover plate and the casting stand plate, which can be indirectly determined by the infrared thermometer. After the sprayed repair material is sintered and solidified with the ladle refractory material under the residual temperature of the ladle refractory material and initially cured (adjusted according to the amount of sprayed material to ensure that the sprayed material is not liquid and that it does not collapse due to incomplete sintering after the sintering and solidification after the sintering and solidification), the command starts the trolley drive system to move along the guide rail of the ladle mouth circumference along the direction with the larger size of the casting stand plate and the casting cover plate, and moves to the next repair job. At this point, the spray repair material and the steel ladle refractory are sintered together, while the casting plate and casting cover plate are separated from the casting material under the action of the vibrating motor.

[0025] The control system issues a command to start the trolley motion drive mechanism to control the maintenance trolley to run along the circular guide rail along the circumferential trajectory of the ladle opening, and move to the next repair job; The repair control system precisely moves the repair trolley a step distance (less than or equal to the width of the casting plate) along the circumference of the ladle opening, causing the solidified repair material to detach from the chamber and form a new cavity in its new position. Spraying, vibration, and sintering continue at the new eroded area to repair the newly eroded refractory material at the ladle opening. When the erosion is minor (less refractory material loss, smaller gaps), less sprayed repair material is used, sintering is faster, and the trolley moves more quickly. Conversely, when the gaps are larger, more sprayed repair material is used, sintering is slower, and the trolley moves more slowly. In short, the sprayed repair material must completely fill the gap between the repair trolley and the ladle opening refractory material. The amount of sprayed repair material used is controlled by valves and the speed of the repair trolley. When the trolley moves during the repair process, the area behind it that has been filled and sintered has a certain sealing effect on the spray irrigation repair material in front, which is conducive to the compression and filling of the subsequent spray irrigation material, thus ensuring the effect of spray irrigation repair.

[0026] S7. After the maintenance trolley moves in a circle once, turn off the repair material spraying system, the trolley motion drive mechanism and the vibration system; Start the lifting support, lift the pouring template, move the repair trolley out of the repair position, and the repair work at the ladle opening is completed. Then proceed with the normal ladle loading operation (replace the slide plate and sprue, clean the ventilated brick residue, fill with sand, etc.).

[0027] Compared with the prior art, the beneficial effects of the present invention are: 1. Significantly improves repair quality and service life (core technical effect) Revolutionary improvement in repair layer density: The vibration system integrated into the repair chamber, combined with the conical cavity design of the casting chamber (larger at the front and smaller at the back), generates a dual effect of continuous "vibrational liquefaction" and "dynamic mechanical extrusion" on the repair material during the spraying process. This effectively removes air bubbles from the slurry, forces particle rearrangement, significantly reduces porosity, and enables the repair body to achieve a bulk density and room temperature / hot strength close to or even reaching the level of the original castable material, fundamentally overcoming the shortcomings of traditional sprayed layers being loose.

[0028] Excellent overall integrity in circumferential seam repair: The device continuously moves along a preset circular trajectory for repair, combined with hot self-sintering achieved by utilizing the residual heat of the ladle, ensuring seamless connection and uniform curing of the repair material within the annular area. This avoids cold seams and weak zones caused by segmented repair, forming a complete reinforced ring with consistent mechanical and corrosion resistance properties, greatly improving the overall lifespan of the ladle seam area.

[0029] 2. Significantly improve operational efficiency and the level of intelligence (production benefits) Work efficiency has been doubled: the system has achieved a leap from "manual intermittent patching" to "mechanized continuous circumferential repair". The device automatically completes the cycle of spraying, vibration and stepping movement, and can complete the maintenance of the entire ladle opening in a single operation, reducing the traditional process that takes several hours to within tens of minutes, and significantly reducing the maintenance time for ladle turnover.

[0030] Adaptive and precise control of process parameters: By integrating infrared temperature measurement, preset material parameter packages and intelligent control system, the device can automatically match the optimal vibration frequency, resting time and moving speed according to the real-time monitoring of the curing state of the repair material and the selected material model, so as to achieve "one-click" precise repair, reduce the dependence on the operator's experience and ensure quality stability.

[0031] 3. Effectively reduce overall costs and resource consumption (economic benefits) Reduced refractory material consumption: High-quality repair layers extend service life, reducing the frequency of repairs at the ladle joint within the same service life. Simultaneously, precise spraying control avoids material waste, significantly reducing the cost of refractory materials per ton of steel.

[0032] Extending the overall lifespan of the ladle: By strengthening the ladle opening, which is the weakest link, the safe service life of the ladle is extended, the overhaul time is postponed, and the utilization rate of the ladle is improved.

[0033] Reduced maintenance costs: Mechanized operations reduce the need for a large number of skilled workers, thereby lowering labor costs and related training and management costs.

[0034] 4. Fundamentally improve working conditions and safety (safety and social benefits) Achieving "human-machine separation" and ensuring personal safety: Operators can complete all repair work in a control room away from high temperatures, dust and potential mechanical injuries, completely eliminating major safety risks such as burns, suffocation and crushing injuries under traditional maintenance methods.

[0035] Improved occupational health environment: It avoids workers being directly exposed to high temperature radiation and refractory material dust, greatly improving working conditions and meeting the stringent requirements of modern industry for occupational health and safety (EHS).

[0036] 5. Promote stable production and system upgrades (operational efficiency) Ensuring stable and smooth production: Fast and reliable ladle maintenance reduces unplanned casting stoppages or production interruptions caused by unstable ladle conditions, providing a solid guarantee for a continuous and efficient steelmaking-continuous casting production rhythm, which is especially beneficial to the stable production of high-quality special steel.

[0037] Easy to integrate and upgrade: This device can be integrated as an independent module into the existing "Lava Full-Process Online Hot Repair System" or the future "Intelligent Ladle Management Platform". It is a key link in promoting the development of ladle maintenance towards full automation, intelligence and unmanned operation, and improves the modernization level of the entire production process.

[0038] This invention not only provides a new repair tool, but also a high-quality, high-efficiency, high-safety, and low-cost ladle opening maintenance system solution. It directly addresses industry pain points, achieving a leap in repair work from quantity to quality through technological innovation, demonstrating clear industrial application value and broad prospects for promotion. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the refractory repair device for the ladle opening; Figure 2 A schematic diagram of the structure for casting the vertical slab; Figure 3 A schematic diagram of the structure of the casting cover plate; Figure 4 This is a schematic diagram of the refractory repair system for the ladle opening; In the diagram, there is a maintenance platform 100, a circular guide rail 1, a maintenance trolley 2, a repair material spraying system 3, and a vibration system 4. 21. Car body; 22. Car motion drive mechanism; 23. Lifting bracket; 24. Cantilever beam; 25. Casting template; Casting chamber 200; Positioning system 5, positioning beam 51, telescopic rod 52, spring 53, roller 54, sliding groove 511; Casting slab 251, casting cover plate 252; 31. Spray gun nozzle, 32. Spraying metal tube, 33. Spraying hose, 34. Material tank, 35. Control valve. Detailed Implementation

[0040] The invention described above will be further explained in conjunction with the accompanying drawings, but is not limited thereto.

[0041] The ladle is a large tool connecting the converter, holding molten steel, and performing ladle refining and casting. With the increasing variety of special steels and the deepening of steel refining processes, the operating environment of the ladle has become increasingly harsh. Improving the service life of the ladle and reducing refractory material consumption while ensuring safe use, within the requirements of steel cleanliness and carbon content, remains a major research topic in the refractory materials industry. Due to high-temperature slag erosion at the slag line, frequent and repeated high-temperature-cooling cycles, and mechanical damage including from anchor hooks during cleaning, refractory material maintenance at the ladle opening has always been a bottleneck and key factor in limiting the ladle's service life. It is also a prerequisite and foundation for safe production and the longevity of the ladle.

[0042] like Figures 1-3 As shown, this embodiment provides a vibration-based refractory repair device for steel ladle openings, including a repair platform 100, a circular guide rail 1, a repair trolley 2, a repair material spraying system 3, a vibration system 4, and a control system.

[0043] The maintenance platform 100 has a ladle placement area in the middle, and the maintenance platform 100 is located above the ladle placement area. The circular guide rail 1 is set on the maintenance platform 100 and located outside the ladle placement area. The ladle placement area is set at the center of the circular guide rail 1 to ensure that the ladle and the circular guide rail 1 are placed coaxially.

[0044] The maintenance trolley 2 includes a trolley body 21, a trolley motion drive mechanism 22, a lifting bracket 23, a cantilever beam 24, and a casting template 25. The trolley body 21 is positioned above the circular guide rail 1. The trolley motion drive mechanism 22 and the lifting bracket 23 are mounted on the trolley body 21. The cantilever beam 24 is horizontally positioned at the upper end of the lifting bracket 23, and the casting template 25 is positioned at the end of the cantilever beam 24. The trolley motion drive mechanism 22 includes a drive motor and four wheels. The four wheels of the trolley body 21 are driven by the drive motor and move in a circular motion along the circular guide rail 1 fixed to the maintenance platform. The lifting bracket 23 is a lifting column with a hydraulic rod structure.

[0045] The casting template 25 is used to form a casting chamber 200 with the inner wall of the ladle. The casting chamber 200 has a front side with the running direction of the maintenance trolley 2 as the front side, and its front space is larger than its rear space.

[0046] The repair material spraying system 3 is installed on the trolley body 21 and is used to inject repair material into the pouring chamber 200; The vibration system 4 is installed on the casting template 25 and is used to vibrate the repair material in the casting chamber 200; The control system is connected to the trolley motion drive mechanism 22, the lifting bracket 23, the repair material spraying system 3, and the vibration system 4. The control system is a PLC / industrial PC, integrating motion control (walking, lifting), process control (spraying, vibration, air / water), and logic sequence control. "Air" refers to the conveying gas, typically compressed air, used to spray the repair material; "water" is used to mix the repair material. The repair material is actually a mixture of repair material and water; after being sprayed from the spray gun, the flowing mixture adheres to the refractory material at the sintering point for sintering.

[0047] The vibration-based refractory repair device for steel ladle openings also includes a positioning system 5, which comprises a positioning beam 51, a telescopic rod 52, a spring 53, and a roller 54.

[0048] The positioning beam 51 is laterally mounted on the trolley body 21. The positioning beam 51 can be an electrically operated telescopic rod or a hydraulically operated telescopic rod.

[0049] The positioning beam 51 has a sliding groove 511 along its axial direction at one end. The telescopic rod 52 is slidably disposed within the sliding groove 511. One end of the telescopic rod 52 is connected to the inner wall of the sliding groove 511 via a spring 53. The roller 54 is rotatably disposed at the other end of the telescopic rod 52. The roller 54 rolls in contact with the outer wall of the ladle, providing support and reducing friction.

[0050] The positioning beam is located between the ladle shell and the trolley support column. The end of the positioning beam near the ladle shell is equipped with a spring and roller to facilitate seamless pouring of the vertical plate and the inner surface of the ladle refractory.

[0051] The casting template 25 includes a casting upright plate 251 and a casting cover plate 252. The casting upright plate 251 is vertically positioned below the cantilever beam 24, and the casting cover plate 252 is horizontally positioned on the casting upright plate 251. The casting upright plate and the casting cover plate are welded together from wear-resistant steel plates. Both the casting upright plate 251 and the casting cover plate 252 are metal plates.

[0052] like Figure 2 and Figure 3As shown, the cross-section of the casting plate 251 and the side wall of the ladle opening, and the cross-section of the casting cover plate 252 and the ladle opening are respectively set at acute angles. The casting plate and cover plate are widened and heightened at their front ends in the direction of trolley movement, forming a conical cavity that is larger at the front and smaller at the back. The principle of the method is to enhance the density of the repair layer by utilizing the continuous mechanical compression of the incompletely cured repair material in front of the conical cavity during the movement of the trolley. The front ends of the casting plate 251 and the casting cover plate 252 are raised, which is equivalent to a trumpet mouth, loose at the front and tight at the back, and gradually dynamically compacted as the trolley moves forward (in conjunction with vibration). That is, a natural "wedge" effect is formed in the direction of trolley movement, which can continuously apply lateral pressure to the repair material in front, and with the help of vibration, achieve dynamic compression and compaction. The "conical leading compaction" mechanism overcomes the shortcomings of uneven density in traditional static spraying.

[0053] The repair material spraying system 3 includes a spray gun nozzle 31, a spray metal pipe 32, a spray hose 33, a material tank 34, a control valve 35, and a compressed gas supply system.

[0054] The spray gun nozzle 31 is inserted into the casting cover plate 252 and communicates with the casting chamber 200.

[0055] The spray gun nozzle 31 is connected in sequence to the spray metal pipe 32, the spray hose 33, and the material tank 34. The spray hose 33 is equipped with a control valve 35, and the spray metal pipe 32 is fixed on the cantilever beam 24.

[0056] The material tank 34 is connected to a compressed gas supply system. Compressed air is directly connected to the compressed air pipeline within the plant, and the spraying pressure is controlled by a pressure regulating valve. The pressure after the pressure regulating valve is the spraying pressure. The material tank 34 is also connected to a water source via a separate pipeline for mixing the repair material. Alternatively, a compressor fan can be installed on the trolley itself as part of the compressed gas supply system.

[0057] The vibration system 4 includes at least one variable frequency vibration motor, the frequency of which can be adjusted within the range of 20-60Hz. The variable frequency vibration motor is installed at the angle between the casting vertical plate 251 and the casting cover plate 252. The vibration motor (or vibration table) is directly fixed at the angle formed by the casting vertical plate and the casting cover plate to achieve direct compaction of the repair material.

[0058] The vibration system 4 includes two variable frequency vibration motors, which are asymmetrically arranged on both sides of the casting chamber 200.

[0059] The base circle radius of the circular guide rail 1 and the working surface curvature radius of the casting upright 251 are both matched with the designed curvature radius of the inner lining of the target ladle. The trolley body 21, the casting upright, and the casting cover plate are all arc-shaped to match the curvature of the ladle opening. The arc-shaped frame of the trolley body 21 adopts a modular or adjustable design to adapt to ladles of different specifications.

[0060] A vibration-based refractory repair system for ladle openings includes the vibration-based refractory repair device for ladle openings as described in this embodiment, and also includes a detection system.

[0061] like Figure 4 As shown, the detection system includes a laser scanner and an infrared temperature measuring device positioned above the ladle. The laser scanner is used to acquire the erosion morphology of the ladle and generate a three-dimensional model of the erosion profile. The infrared temperature measuring device is used to collect the real-time temperature of the casting mold 25. The laser scanner and the infrared temperature measuring device can be rotated around the ladle axis via a rotating mechanism.

[0062] The control system calculates the erosion depth and relative area based on the morphology of the eroded area using a model. Based on a self-built database, it determines the corresponding repair parameters, including the amount of repair material, the vibration frequency of the vibration system 4, and the sintering time. The calculation method for erosion depth and relative area is existing technology and will not be elaborated here.

[0063] The self-built database contains different repair parameters corresponding to different erosion morphologies, which are obtained by collecting data from laser scanners, infrared thermometers, and historical data of repair parameters.

[0064] This method introduces a step for calculating repair volume and planning the path based on laser scanning of the erosion profile. Specifically, a laser scanning device is positioned near the repair area to detect the erosion depth and area of ​​the refractory material before repair, calculating the required amount of repair material. This provides a basis for the movement of the repair trolley and the amount of material applied. For example, this invention can automatically or manually adjust the matching method between the sprayed material flow rate and the trolley's moving speed according to the degree of erosion (gap size) to achieve full and efficient repair.

[0065] An infrared temperature measuring device is installed near the area above the repair site to monitor the temperature of the repair material and its sintering time. Alternatively, a control system can be implemented that automatically matches different repair material models based on preset process parameter packages.

[0066] The vibration-based refractory repair system for steel ladles also includes an operating interface.

[0067] The operation interface (HMI) is used to input setting parameters (type of repair material, lifting height, etc.), display equipment status (whether the spray gun is spraying, the repair trolley is moving, the vibration table, the lifting mechanism, the trolley drive motor, etc. are running) and alarm information (lifting mechanism not in position, insufficient pressure in the repair material tank, drive motor failure, vibration table vibration motor failure, etc.).

[0068] The control system interlocks the trolley motion drive mechanism 22, the lifting bracket 23, and the repair material spraying system 3. If the lifting bracket 23 is not in position, the trolley motion drive mechanism 22 is prohibited from operating, and the repair material spraying system 3 will suspend spraying if the pressure is insufficient, thus achieving a safety interlock. The upper and lower limits of the lifting are equipped with limit triggering devices and sensor signal feedback. The pressure of the repair material spraying system 3 is detected by a pressure gauge. After the data is collected, it is compared with the set pressure threshold, and an interlock alarm is triggered. When the pressure in the repair material tank is insufficient, an alarm is triggered and spraying is suspended.

[0069] A vibration-based method for repairing refractory material at the mouth of a steel ladle, utilizing the vibration-based refractory material repair system of this embodiment, includes the following steps: S1. Based on the corrosion status of the ladle and the production schedule, determine whether ladle repair is necessary. The specific criteria can be determined by setting thresholds for corrosion depth and relative area, as well as by considering the production cycle. Those skilled in the art can set these criteria based on their actual production experience.

[0070] S2. When ladle repair is required, after the ladle has been poured on the continuous casting machine, the overhead crane will be used to remove the remaining steel slag from the ladle.

[0071] S3. Hoist the ladle to the ladle placement area of ​​the maintenance platform 100, with the ladle opening facing vertically upwards, so that the ladle is coaxial with the circular guide rail 1.

[0072] S4. Start the lifting support 23, raise the casting template 25, move the repair trolley 2 to the repair position, and then lower the casting template 25. The casting template 25 and the inner wall of the ladle form a casting chamber 200. In this embodiment, the lower part of the casting plate is brought close to the ladle refractory material without gap under the action of the positioning beam spring, realizing the adaptive seamless fit between the casting plate and the ladle lining, and maintaining the stability of the casting template 25.

[0073] S5. Start the repair material spraying system 3 and inject the repair material into the pouring chamber 200 for pouring and repair.

[0074] At the same time, the vibration system 4 is activated to compact the repair material.

[0075] S6. Precise control of process detection and feedback in the "sprinkler-vibration-sintering-movement" sequence: An infrared thermometer is used to monitor the temperature of the casting template 25 in real time. The control system controls the sintering completion time based on the temperature of the casting template 25. Through a preset delay program, the control system automatically determines that sintering is complete. In this embodiment, the residual heat of the ladle itself is used as the heat source required for the solidification of the repair material, eliminating the need for an additional baking device.

[0076] The control system issues a command to start the trolley motion drive mechanism 22 to control the maintenance trolley 2 to run along the circular guide rail 1 of the steel ladle opening, and move to the next repair job.

[0077] S7. After the maintenance trolley moves in a circle once, shut down the repair material spraying system 3, the trolley motion drive mechanism 22, and the vibration system 4.

[0078] Start the lifting support 23, lift the pouring template 25, move the repair trolley out of the repair position, the repair work of the ladle opening is completed, and normal loading operation can be carried out.

[0079] This invention employs the following repair sequence: positioning and bonding → spraying and synchronous vibration → static sintering using residual heat of the package body until preliminary solidification → stepping and moving to the next workstation. Automated repair is achieved by utilizing the specific timing logic of "vibration while spraying and pouring" and "moving after sintering and shaping." This transforms the most arduous and dangerous task of repairing package seams from manual labor into a mechanized and procedural operation, significantly reducing safety risks, labor intensity, and skill dependence. Simultaneously, vibration combined with mechanical compression ensures uniform density and strength of the repaired material, avoiding the instability of manual operation and contributing to an extended overall service life after repair.

Claims

1. A vibration-based refractory repair device for steel ladle openings, characterized in that: It includes a maintenance platform (100), a circular guide rail (1), a maintenance trolley (2), a repair material spraying system (3), a vibration system (4), and a control system; The maintenance platform (100) has a ladle placement area in the middle, and the circular guide rail (1) is set on the maintenance platform (100) and located outside the ladle placement area; The maintenance trolley (2) includes a trolley body (21), a trolley motion drive mechanism (22), a lifting bracket (23), a cantilever beam (24), and a casting template (25). The trolley body (21) is located above the circular guide rail (1). The trolley motion drive mechanism (22) and the lifting bracket (23) are located on the trolley body (21). The cantilever beam (24) is horizontally located at the upper end of the lifting bracket (23). The casting template (25) is located at the end of the cantilever beam (24). The casting template (25) is used to form a casting chamber (200) with the inner wall of the ladle. The casting chamber (200) has its front side facing the direction of the maintenance trolley (2), and its front space is larger than its rear space. The repair material spraying system (3) is installed on the trolley body (21) and is used to inject repair material into the pouring chamber (200); The vibration system (4) is installed on the casting template (25) and is used to vibrate the repair material in the casting chamber (200); The control system is connected to the trolley motion drive mechanism (22), the lifting bracket (23), the repair material spraying system (3), and the vibration system (4).

2. The vibration-based refractory repair device for steel ladle openings according to claim 1, characterized in that: It also includes a positioning system (5), which includes a positioning beam (51), a telescopic rod (52), a spring (53) and a roller (54). The positioning beam (51) is laterally arranged on the trolley body (21); The positioning beam (51) has a sliding groove (511) at its end. The telescopic rod (52) is slidably disposed in the sliding groove (511). One end of the telescopic rod (52) is connected to the inner wall of the sliding groove (511) by a spring (53). The roller (54) is rotatably disposed at the other end of the telescopic rod (52).

3. The vibration-based refractory repair device for steel ladle openings according to claim 1, characterized in that: The casting template (25) includes a casting upright plate (251) and a casting cover plate (252). The casting upright plate (251) is vertically arranged below the cantilever beam (24), and the casting cover plate (252) is horizontally arranged on the casting upright plate (251). The pouring plate (251) and the cross-section of the side wall of the ladle opening, and the pouring cover plate (252) and the cross-section of the ladle opening are respectively set at acute angles.

4. The vibration-based refractory repair device for steel ladle openings according to claim 3, characterized in that: The repair material spraying system (3) includes a spray gun nozzle (31), a spray metal pipe (32), a spray hose (33), a material tank (34), a control valve (35), and a compressed gas supply system; The spray gun nozzle (31) is inserted on the casting cover plate (252) and communicates with the casting chamber (200); The spray gun nozzle (31) is connected in sequence to the spray metal pipe (32), the spray hose (33), and the material tank (34). The spray hose (33) is equipped with a control valve (35), and the spray metal pipe (32) is fixed on the cantilever beam (24). The material tank (34) is connected to the compressed gas supply system.

5. The vibration-based refractory repair device for steel ladle openings according to claim 3, characterized in that: The vibration system (4) includes at least one variable frequency vibration motor, which is located at the angle between the casting plate (251) and the casting cover plate (252).

6. The vibration-based refractory repair device for steel ladle openings according to claim 5, characterized in that: The vibration system (4) includes two variable frequency vibration motors, which are asymmetrically arranged on both sides of the casting chamber (200).

7. The vibration-based refractory repair device for steel ladle openings according to claim 3, characterized in that: The base circle radius of the circular guide rail (1) and the working surface curvature radius of the casting plate (251) are both matched with the design curvature radius of the inner lining of the target ladle.

8. A vibration-based refractory repair system for ladle openings, comprising the vibration-based refractory repair device for ladle openings as described in any one of claims 1-7, characterized in that: It also includes a detection system; The detection system includes a laser scanner and an infrared temperature measuring device set above the ladle. The laser scanner is used to acquire the erosion morphology of the ladle and generate a three-dimensional model of the erosion profile. The infrared temperature measuring device is used to collect the real-time temperature of the casting template (25). The control system calculates the erosion depth and relative area based on the morphology of the eroded area, and determines the corresponding repair parameters based on a self-built database. The self-built database contains different repair parameters corresponding to different erosion morphologies, which are obtained by collecting data from laser scanners, infrared thermometers, and historical data of repair parameters.

9. The vibration-based refractory repair system for ladle openings according to claim 8, characterized in that: It also includes the user interface; The user interface is used to input setting parameters, display device status, and alarm information; The control system interlocks the trolley motion drive mechanism (22), the lifting bracket (23), and the repair material spraying system (3). If the lifting bracket (23) is not in place, the trolley motion drive mechanism (22) is prohibited from operating, and the repair material spraying system (3) will stop spraying if the pressure is insufficient.

10. A vibration-based method for repairing refractory material at the mouth of a steel ladle, comprising the vibration-based refractory material repair system of claim 9, characterized in that, Includes the following steps: S1. Determine whether ladle repair is necessary based on the ladle corrosion and production schedule; S2. When ladle repair is required, after the ladle has been poured in the continuous casting machine, the overhead crane will be used to remove the remaining steel slag from the ladle. S3. Hoist the ladle to the ladle placement area of ​​the maintenance platform (100), with the ladle opening facing vertically upward; S4. Start the lifting support (23), raise the casting template (25), move the repair trolley (2) to the repair position, and then lower the casting template (25). The casting template (25) and the inner wall of the ladle form a casting chamber (200). S5. Start the repair material spraying system (3) and inject the repair material into the pouring chamber (200) for pouring repair; At the same time, the vibration system (4) is started to compact the repair material; S6. Precise control of process detection and feedback in the "sprinkler-vibration-sintering-movement" sequence: The temperature of the casting template (25) is monitored in real time using an infrared temperature measuring device, and the control system controls the sintering completion time according to the temperature of the casting template (25). The control system starts the trolley motion drive mechanism (22) to control the maintenance trolley (2) to run along the circular guide rail (1) of the circumferential trajectory of the steel ladle opening and move to the next work repair; S7. After the maintenance trolley moves in a circle, shut down the repair material spraying system (3), the trolley motion drive mechanism (22), and the vibration system (4). Start the lifting support (23), lift the pouring template (25), move the repair trolley out of the repair position, the repair work of the ladle opening is completed, and normal packing operation is carried out.

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