A smart probe measuring device for the working end length of an electrode in a calcium carbide furnace

Abstract

This utility model discloses an intelligent probe measuring device for the working end length of a calcium carbide furnace electrode, belonging to the field of calcium carbide furnace production technology. It solves the problems currently faced in calcium carbide production processes where, due to the lack of specialized measuring devices for the working end length of electrodes, manual measurement is commonly used, often resulting in high labor intensity for operators, inaccurate measurement results, low measurement efficiency, and high safety risks. This utility model features a trolley with a frame, and sliding wheels at the end of the frame. A probe measuring rod forward and backward propulsion mechanism slides on the sliding wheels. The probe measuring rod forward and backward propulsion mechanism includes a probe measuring rod replacement and length measuring device and a probe measuring rod angle rotation mechanism. The probe measuring rod replacement and length measuring device is equipped with a probe measuring rod, and probe measuring rod horizontal height positioning devices are located at the four ends of the trolley. This utility model achieves centimeter-level accuracy measurement of the electrode working end length, significantly improving accuracy compared to traditional manual measurement, and providing reliable data support for production process optimization.

Description

Technical Field

[0001] This utility model belongs to the field of calcium carbide furnace production technology, specifically relating to an intelligent probe measuring device for the working end length of a calcium carbide furnace electrode. Background Technology

[0002] In the calcium carbide production process, the length of the electrode working end is a key parameter affecting production efficiency, product quality, and energy consumption. A suitable electrode working end length ensures arc stability, reduces energy consumption, minimizes electrode wear, and improves calcium carbide yield and quality. However, traditional electrode working end length measurement relies primarily on manual operation. Operators must operate in harsh environments such as high temperatures, dust, and strong magnetic fields, holding measuring tools and relying on observation and experience to make measurements. This method is not only inaccurate and inefficient but also poses significant safety hazards, easily leading to burns, electric shocks, and other accidents for operators. With the advancement of automated and intelligent production in the calcium carbide industry, traditional measurement methods can no longer meet the requirements of modern production for high precision, high efficiency, and safety. There is an urgent need to develop an advanced intelligent measuring device to automate and accurately measure the electrode working end length. Utility Model Content

[0003] The purpose of this invention is to provide an intelligent probe measuring device for the working end length of a calcium carbide furnace electrode, in order to solve the problems that currently, in the calcium carbide production process, due to the lack of a professional measuring device for the working end length of the calcium carbide furnace electrode, manual measurement is generally used, which often results in high labor intensity for operators, inaccurate measurement results, low measurement efficiency, and high safety risks.

[0004] The technical solution of this utility model is: an intelligent probe measuring device for the working end length of an electrode in a calcium carbide furnace, comprising a trolley, a frame on the trolley, a slide rail wheel at the end of the frame, a probe measuring rod forward and backward propulsion mechanism sliding on the slide rail wheel, a probe measuring rod replacement and length measuring device and a probe measuring rod angle rotation mechanism on the probe measuring rod forward and backward propulsion mechanism, a probe measuring rod on the probe measuring rod replacement and length measuring device, and probe measuring rod horizontal height positioning devices at the four ends of the trolley.

[0005] As a further improvement of this utility model, the car includes a frame, with a front steering wheel and a rear drive wheel at the bottom of the frame. The front steering wheel is connected by a front wheel axle, and the front wheel axle is connected to a steering motor via a rotating shaft. The rear drive wheel is connected by a drive shaft, and a car motor is mounted on the drive shaft. A servo drive chassis is also provided at the bottom of the frame, and a battery compartment is provided on the servo drive chassis. A protective cover and a shell are provided on the side of the frame.

[0006] As a further improvement of this utility model, the probe rod replacement and length measuring device includes a guide rod connected to the probe rod via a mechanical clamp, a guide sleeve at the connection between the guide rod and the probe rod, a lead screw support arranged side by side on the side of the guide rod, the lead screw support being connected to the guide rod via a coupling, the coupling being connected to a first motor, a first lead screw at the end of the guide rod, the first lead screw being connected to the lead screw support via a first lead screw nut, a head guide sleeve between the end of the guide rod and the lead screw support, and a laser measuring device at the connection between the guide rod and the probe rod.

[0007] As a further improvement of this utility model, the horizontal height positioning device for the probe rod includes a hydraulic lifting system, and a high-precision displacement sensor is provided at the upper end of the hydraulic lifting system.

[0008] As a further improvement of this utility model, the probe rod forward and backward propulsion mechanism includes a second lead screw, which is mounted on the slide rail wheel. A mounting bracket is connected to the second lead screw via a second lead screw nut. A bearing seat is provided at the end of the second lead screw, and a second motor is connected to the bearing seat via a lead screw coupling.

[0009] As a further improvement of this utility model, the probe angle rotation mechanism includes a rotating bracket, a rotating shaft on the rotating bracket, a gear at one end of the rotating shaft, a servo electric cylinder connected to the gear, and a rack meshing with the gear, which is mounted on a rack slide rail.

[0010] As a further improvement of this utility model, the trolley, the probe rod replacement and length measuring device, the probe rod horizontal height positioning device, the probe rod forward and backward propulsion mechanism, and the probe rod angle rotation mechanism are connected by PLC electrical signals.

[0011] The beneficial effects of this utility model are as follows: The probe of this invention is inserted into the observation hole on the side wall of the electric furnace hood. The probe is inserted into the lower end of the electrode. The insertion angle and length of the probe are used to calculate the depth of the electrode insertion into the material surface, thereby achieving the purpose of measuring the length of the working end of the electrode.

[0012] The trolley can move 360 ​​degrees forward, backward, left, and right; the probe rod replacement and length measurement device functions to replace the probe rod and measure its length; the probe rod horizontal height positioning device functions to raise the trolley to accommodate different measurement heights; the probe rod forward and backward propulsion mechanism functions to drive the intelligent probe device to move linearly and realize the forward and backward movement of the probe rod; the probe rod angle rotation mechanism functions to realize the 0-45° rotation of the probe rod to adjust the measurement angle; the probe rod insertion has a force feedback function, driving the probe rod to move linearly and insert the electrode for measurement.

[0013] This invention primarily utilizes advanced sensor technology and precise control algorithms to achieve centimeter-level accuracy in measuring the length of the electrode working end, significantly improving accuracy compared to traditional manual measurement and providing reliable data support for production process optimization. It incorporates automatic positioning and navigation functions, enabling the probing vehicle to automatically travel to the target location upon receiving instructions, and features automatic positioning and obstacle avoidance. Operators can remotely control the probing mechanism from the central control room to complete probing tasks, meeting the needs of continuous production in calcium carbide furnaces. Safety measures such as laser automatic obstacle avoidance and gas detection prevent collisions and other accidents during operation, while reducing direct contact between operators and the harsh production environment, lowering safety risks for operators and ensuring the safety of personnel and equipment. Integrating automatic positioning, remote control, data acquisition, wireless control, automatic obstacle avoidance, continuous operation, and measurement data storage into one system, one system can simultaneously serve two calcium carbide furnaces, improving equipment utilization. Automatic acquisition, recording, and uploading of measurement data facilitates integration and analysis with other production data, providing data support for production decisions and assisting enterprises in achieving intelligent production management. Attached Figure Description

[0014] Figure 1 This is a three-dimensional structural view of the present invention; Figure 2 This is a front view of the structure of this utility model; Figure 3 This is the left structural view of the present invention; Figure 4 This is a top view of the structure of this utility model; Figure 5 This is a three-dimensional structural view of the small vehicle of this utility model; Figure 6 This is a three-dimensional structural view of the probe rod replacement and length measuring device of this utility model; Figure 7 This is a top view of the structure of the probe rod replacement and length measuring device of this utility model; Figure 8 This is a three-dimensional structural view of the horizontal height positioning device for the probe rod in this utility model; Figure 9 This is a three-dimensional structural view of the forward and backward propulsion mechanism of the probe rod in this utility model; Figure 10 This is a three-dimensional structural view of the probe angle rotation mechanism in this utility model; Figure 11 This is a schematic diagram of the electrode measurement of this utility model.

[0015] In the diagram: 1-Car; 11-Servo drive chassis; 12-Frame; 13-Cover and shell; 14-Front steering wheel; 15-Rear drive wheel; 16-Drive shaft; 17-Shaft; 18-Front wheel axle; 19-Steering motor; 110-Car motor; 111-Battery compartment; 2-Frame; 3-Slide rails and wheels; 4- Probe rod replacement and length measuring device; 41- Probe rod; 42- Guide rod; 43- Lead screw support; 44- First lead screw nut; 45- First lead screw; 46- Head guide sleeve; 47- Guide sleeve; 48- Coupling; 49- First motor; 410- Mechanical clamp; 411- Laser measuring device; 5-Horizontal positioning device for probe rod; 51-Hydraulic lifting system; 52-High-precision displacement sensor; 6-Propeller mechanism for probe rod; 61-Screw coupling; 62-Bearing housing; 63-Mounting bracket; 64-Second screw nut; 65-Second screw; 66-Second motor; 7-Probe angle rotation mechanism; 71-Rotating bracket; 72-Rotating shaft; 73-Gear; 74-Rack; 75-Rack slide rail; 76-Servo electric cylinder. Detailed Implementation

[0016] like Figures 1-11 As shown, an intelligent probe measuring device for the working end length of an electrode in a calcium carbide furnace includes a trolley 1, a frame 2 on the trolley 1, a slide rail wheel 3 at the end of the frame 2, a probe measuring rod forward and backward propulsion mechanism 6 slidably mounted on the slide rail wheel 3, a probe measuring rod forward and backward propulsion mechanism 6 is provided with a probe measuring rod replacement and length measuring device 4 and a probe measuring rod angle rotation mechanism 7, a probe measuring rod 41 is provided on the probe measuring rod replacement and length measuring device 4, and probe measuring rod horizontal height positioning devices 5 are respectively provided at the four ends of the trolley 1.

[0017] The vehicle 1 includes a frame 12. The bottom of the frame 12 is provided with a front steering wheel 14 and a rear drive wheel 15. The front steering wheel 14 is connected through a front wheel axle 18. The front wheel axle 18 is connected to a steering motor 19 through a shaft 17. The rear drive wheel 15 is connected through a drive shaft 16. The drive shaft 16 is provided with a vehicle motor 110. The bottom of the frame 12 is also provided with a servo drive chassis 11. The servo drive chassis 11 is provided with a battery compartment 111. The side of the frame 12 is provided with a protective cover and a shell 13.

[0018] The probe rod replacement and length measuring device 4 includes a guide rod 42 connected to the probe rod 41 via a mechanical clamp 410. A guide sleeve 47 is provided at the connection between the guide rod 42 and the probe rod 41. A lead screw support 43 is provided side by side on the side of the guide rod 42. The lead screw support 43 is connected to the guide rod 42 via a coupling 48. A first motor 49 is connected to the coupling 48. A first lead screw 45 is provided at the end of the guide rod 42. The first lead screw 45 is connected to the lead screw support 43 via a first lead screw nut 44. A head guide sleeve 46 is also provided between the end of the guide rod 42 and the lead screw support 43. A laser measuring device 411 is also provided at the connection between the guide rod 42 and the probe rod 41.

[0019] The probe rod horizontal height positioning device 5 includes a hydraulic lifting system 51, and a high-precision displacement sensor 52 is provided at the upper end of the hydraulic lifting system 51.

[0020] The probe rod forward and backward propulsion mechanism 6 includes a second lead screw 65, which is mounted on the slide rail wheel 3. A mounting bracket 63 is connected to the second lead screw 65 via a second lead screw nut 64. A bearing seat 62 is provided at the end of the second lead screw 65, and a second motor 66 is connected to the bearing seat 62 via a lead screw coupling 61.

[0021] The probe angle rotation mechanism 7 includes a rotating bracket 71, a rotating shaft 72 on the rotating bracket 71, a gear 73 at one end of the rotating shaft 72, a servo electric cylinder 76 connected to the gear 73, and a rack 74 meshing with the gear 73, which is located on a rack slide rail 75.

[0022] The trolley 1, the probe rod replacement and length measuring device 4, the probe rod horizontal height positioning device 5, the probe rod front and rear propulsion mechanism 6, and the probe rod angle rotation mechanism 7 are connected via PLC electrical signals.

[0023] Example 1 I. Mechanical Part The trolley 1 adopts a structure with front steering wheels 14 for steering and rear drive wheels 15 for drive, with a maximum load of 1.5 tons. Equipped with a servo-driven chassis 11, it can achieve 360° free movement. The probe rod replacement and length measurement mechanism 4, through a laser measuring device 411 and a mechanical clamp 410 in conjunction with a guide rod 42, achieves precise replacement and length measurement of the probe rod 41. The probe rod horizontal height positioning mechanism 5 uses a hydraulic lifting system 51, paired with a high-precision displacement sensor 52, to accurately control the height of the trolley 1, adapting to the measurement needs of different calcium carbide furnaces.

[0024] The probe rod forward and backward propulsion mechanism 6, the probe rod angle rotation mechanism 7, and the probe rod replacement and length measuring device 4 all adopt a motor + reducer drive method, and achieve precise motion control through a PLC control system. The protective cover and outer shell 13 are made of high temperature resistant and dustproof materials, effectively protecting the internal components of the device to work normally in harsh environments.

[0025] II. Control Section The servo-driven chassis 11 of the mobile platform, combined with a 2D LiDAR, constructs an environmental map and uses the SLAM algorithm to achieve dynamic obstacle avoidance and path planning, with a positioning accuracy of ±10cm. The laser measurement device 411 includes a LiDAR, an ultrasonic sensor, a torque sensor, and a gas sensor, which are used for navigation, obstacle avoidance, force feedback, and environmental monitoring, respectively.

[0026] The industrial control computer and PLC in the control center communicate via Ethernet to achieve real-time control of various parts of the device. The wireless communication module adopts 5G technology to ensure real-time transmission of remote control commands and high-speed data upload. The 48V battery pack in the battery compartment 111 uses lithium batteries and, with the help of an automatic charging station, enables continuous operation of the device. The on-board edge computing unit of the data management system processes and stores measurement data locally and synchronizes it with the central database via industrial Ethernet.

[0027] III. Measurement Methods When measuring the length of the electrode working end, the trolley 1 is first moved to the waiting area, and the length calibration program of the probe 41 is started. The laser measuring device 411 measures the length of the probe 41. If the length is insufficient, the mechanical fixture 410 automatically replaces the probe 41 with a new one and recalibrates it. After calibration, the target calcium carbide furnace number and probe hole position information are entered into the control system, and the trolley 1 automatically travels to the designated position via the laser navigation of the laser measuring device 411.

[0028] Upon reaching the measurement position, the probe rod horizontal height positioning device 5 unfolds, the vehicle body posture sensor provides real-time feedback on the vehicle body's levelness, and the PLC control system automatically adjusts the outrigger extension length via the hydraulic lifting system 51 to ensure the vehicle body tilt is ≤0.5°. Operators in the central control room control the probe rod forward and backward propulsion mechanism 6 and the probe rod angle rotation mechanism 7 via a remote video monitoring system to align the probe rod 41 axis with the probe hole and adjust it to the initial angle of 30°.

[0029] Remote control measurement mechanism initialization: 1) Horizontal movement calibration: The operator remotely controls the probe rod forward and backward advance mechanism 6 in the central control room through sensor data and image view to align the axis of the probe rod 41 with the probe hole diameter; 2) Angle pre-adjustment: The probe rod angle rotation mechanism 7 is remotely controlled to the initial probe tilt position (default 30°, can be set remotely); 3) Remote video monitoring: The high-definition video monitoring system is used to remotely monitor the device's running trajectory and guide the operation.

[0030] Then, the step-by-step measurement program is started. The probe rod 41 is inserted at a 30° angle for the first time, and the insertion torque data is monitored in real time. If the torque is greater than or equal to the set value, it is determined to be a contact electrode, the signal is recorded, and the probe is withdrawn. If the torque is less than the set value, the angle is adjusted to 35° for a second measurement. If the torque is still less than the set value in the second measurement, the angle is adjusted to 32° for a third measurement. If the torque is greater than or equal to the set value, it is determined to be a valid contact, and the current angle value is recorded.

[0031] The electrode depth is calculated based on the embedded intelligent algorithm, and the measurement results are automatically uploaded to the central database, including fields such as timestamp, electrode number, angle, and depth.

[0032] Finally, based on the recorded angle value and the calibrated probe length 41, the electrode insertion depth into the material surface is calculated using the formula h=L×sin(a)−H. The measurement results are automatically uploaded to the central database, including fields such as timestamp, electrode number, angle, and depth, for the production management system to access and analyze.

[0033] This utility model also has the following effects: 1. High measurement accuracy: Through advanced sensor technology and precise control algorithms, the length of the electrode working end can be measured with centimeter-level accuracy, which is a significant improvement over traditional manual measurement.

[0034] 2. It has a high degree of automation and intelligence, with automatic positioning, navigation and obstacle avoidance functions. It can be remotely controlled to complete measurement tasks, meet the needs of continuous production of calcium carbide furnaces and improve production efficiency.

[0035] 3. High safety: Through safety measures such as laser automatic obstacle avoidance and gas detection, the device avoids collision accidents, reduces the operator's contact with harsh environments, and lowers safety risks.

[0036] 4. High degree of functional integration: It integrates functions such as automatic positioning, remote control, data acquisition, wireless control, automatic obstacle avoidance, and data storage into one system. One system can serve two calcium carbide furnaces at the same time, improving equipment utilization.

[0037] 5. Convenient data management enables automatic collection, recording, and uploading of measurement data, facilitating integration and analysis with other production data, providing data support for production decisions, and contributing to intelligent production management.

Claims

1. An intelligent probe measuring device for the working end length of an electrode in a calcium carbide furnace, characterized in that: Includes a trolley (1), on which a frame (2) is provided, and at the end of the frame (2) a slide rail wheel (3) is provided, on which a probe rod forward and backward propulsion mechanism (6) is slidably provided, on which a probe rod exchange and length measuring device (4) and a probe rod angle rotation mechanism (7) are provided, on which a probe rod exchange and length measuring device (4) is provided, and at the four ends of the trolley (1) a probe rod horizontal height positioning device (5) is provided respectively.

2. The intelligent electrode end length measurement device for calcium carbide furnace according to claim 1, characterized in that: The vehicle (1) includes a frame (12), with a front steering wheel (14) and a rear drive wheel (15) at the bottom of the frame (12). The front steering wheel (14) is connected by a front wheel axle (18), and the front wheel axle (18) is connected to a steering motor (19) via a rotating shaft (17). The rear drive wheel (15) is connected by a drive shaft (16), and a vehicle motor (110) is provided on the drive shaft (16). A servo drive chassis (11) is also provided at the bottom of the frame (12), and a battery compartment (111) is provided on the servo drive chassis (11). A protective cover and a shell (13) are provided on the side of the frame (12).

3. The intelligent electrode stub length measuring device for calcium carbide furnace according to claim 1, characterized in that: The probe rod replacement and length measuring device (4) includes a guide rod (42) connected to the probe rod (41) via a mechanical clamp (410). A guide sleeve (47) is provided at the connection between the guide rod (42) and the probe rod (41). A screw support (43) is provided side by side on the side of the guide rod (42). The screw support (43) is connected to the guide rod (42) via a coupling (48). A first motor (49) is connected to the coupling (48). A first screw (45) is provided at the end of the guide rod (42). The first screw (45) is connected to the screw support (43) via a first screw nut (44). A head guide sleeve (46) is also provided between the end of the guide rod (42) and the screw support (43). A laser measuring device (411) is also provided at the connection between the guide rod (42) and the probe rod (41).

4. The intelligent electrode stub measuring device for calcium carbide furnace according to claim 1, characterized in that: The probe rod horizontal height positioning device (5) includes a hydraulic lifting system (51), and a high-precision displacement sensor (52) is provided at the upper end of the hydraulic lifting system (51).

5. The intelligent probe measuring device for the working end length of an electrode in a calcium carbide furnace according to claim 1, characterized in that: The probe rod forward and backward propulsion mechanism (6) includes a second lead screw (65), which is mounted on the slide rail wheel (3). A mounting bracket (63) is connected to the second lead screw (65) via a second lead screw nut (64). A bearing seat (62) is provided at the end of the second lead screw (65), and a second motor (66) is connected to the bearing seat (62) via a lead screw coupling (61).

6. The intelligent probe measuring device for the working end length of a calcium carbide furnace electrode according to claim 1, characterized in that: The probe angle rotation mechanism (7) includes a rotating bracket (71), a rotating shaft (72) is provided on the rotating bracket (71), a gear (73) is provided at one end of the rotating shaft (72), the gear (73) is connected to a servo electric cylinder (76), the gear (73) is also meshed with a rack (74), and the rack (74) is provided on a rack slide rail (75).

7. The intelligent probe measuring device for the working end length of a calcium carbide furnace electrode according to any one of claims 1-6, characterized in that: The trolley (1), the probe rod replacement and length measuring device (4), the probe rod horizontal height positioning device (5), the probe rod forward and backward propulsion mechanism (6), and the probe rod angle rotation mechanism (7) are connected by PLC electrical signals.

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