Remote operation system

Abstract

To provide a remote operation system which can utilize the skill of a furnace construction operator and can reduce a time required for furnace construction.SOLUTION: Provided is a remote operation system for installing refractories including shaped refractories (101) and unshaped refractories (14) in a cylindrical kiln (1), and comprises: a robot (17) for executing a predetermined operation to the shaped refractories as operation objects; a measuring instrument for measuring the positions of the operation objects; and installing means (16) which is provided at the robot and is brought into contact with the operation objects, and it is configured in such a manner that an operator for operating the robot perceives reaction force that the installing means receives from the operation objects.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a remote operation system. In particular, the present disclosure relates to a remote operation system for constructing refractories including shaped refractories and unshaped refractories in refining vessels such as converters and torpedo cars used in the iron and steel industry.

Background Art

[0002] Refining vessels are lined with refractories. Refractories can be classified into shaped refractories and unshaped refractories. A typical example of a shaped refractory is a refractory brick. In particular, in parts where chemical damage by slag is severe, such as parts where scrap is charged, bricks, which are shaped refractories, are used. A craftsman called a bricklayer constructs by stacking each brick one by one. In recent years, the number of bricklayers has been on a decreasing trend.

[0003] In the production of refractory bricks, refractory aggregates are bonded with a binder, the mixed clay is filled into a metal mold, and press molding is performed. Unfired bricks are made by volatilizing the organic components in the binder at about 200°C after press molding. Also, fired bricks are made by firing at a high temperature exceeding 1000°C after press molding. A typical example of an unfired brick is an MgO-C brick used as a wear brick in ladles and converters. Also, typical examples of fired bricks are magnesia bricks or high alumina bricks. Since these shaped bricks use a plurality of metal molds for press molding when manufacturing one type of brick, the size of the refractory brick varies depending on the size of the metal mold. Also, the size of each brick varies due to springback occurring after molding or sintering shrinkage due to firing. During construction (lining), products within the tolerance range are used. Here, the tolerance has the meaning shown in "JIS Z 8103:2000 Terms of Measurement".

[0004] When bricks used as the inner lining of a container are made longer in the depth direction, the inner diameter of the container becomes smaller, and the amount of molten metal that can enter the container decreases, which is not preferable. On the other hand, when the depth direction is made shorter, there is a risk that the container will reach a temperature higher than the endurance temperature due to the energy transferred from the molten metal to the iron skin of the container. Therefore, there is an appropriate range of length in the depth direction for the bricks. Also, the width of the bricks needs to be determined considering "seri". Here, "seri" is the thermal stress acting in the circumferential direction when the bricks, which become hot during the use of the refining container, expand due to thermal expansion. If "seri" is large, the bricks may crack. On the other hand, if "seri" is too small, the bricks may fall off. For example, by absorbing the expansion of the bricks at the gap (joint) between adjacent bricks, the influence of "seri" can be reduced. The height of the bricks also needs to be determined considering "seri", similar to the width. In this way, according to the usage conditions of the refining container to be used, the appropriate ranges of length in the depth direction, width direction, and height direction of the bricks used as the inner lining of the container are determined. On the other hand, from the perspective of construction efficiency, it is preferable that the larger each brick is, the fewer the total number of bricks used in construction. However, there is a limitation that if each brick is too heavy, it cannot be carried by the bricklayer.

[0005] As a method of mechanizing the construction work, for example, Patent Document 1 proposes a refractory construction method including a step of constructing wear bricks based on the operating surface of the wear bricks after construction, and a step of pouring permacastable into the gap between the back surface of the constructed wear bricks and the iron skin.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] Here, the refining vessel deforms due to thermal stress and the like during use. When the deformation of the refining vessel is large, repair is performed by partially melting the metal of the iron skin and replacing it with new metal. In such a repair, since the new metal is joined by welding, a step of about 10 mm may occur. Thus, the vessel may be different from the drawing shape. For example, if the gap between adjacent bricks increases due to the influence of a step in the vessel, the bricks are likely to be peeled and damaged. On the other hand, the bricklayer constructs in accordance with each vessel shape in consideration of such an influence.

[0008] In the technique described in Patent Document 1, since construction is performed using a robot arm, if large and heavy bricks are used, the construction time can be shortened. However, construction considering the deformation of the refining vessel like a bricklayer cannot be performed. Therefore, peeling damage and the like occur, the life of the bricks is shortened, and the number of repairs of the refining vessel increases, so the effect of shortening the above construction time is impaired.

[0009] An object of the present disclosure is to provide a remote operation system that can utilize the skills of a bricklayer and can shorten the time required for construction.

Means for Solving the Problems

[0010] (1) A remote operation system according to an embodiment of the present disclosure is a remote operation system for constructing a refractory including a shaped refractory and an unshaped refractory in a kiln having a cylindrical shape, a robot that uses the shaped refractory as a work object and performs a predetermined operation on the work object, a measuring instrument that measures the position of the work object, and a construction means provided on the robot and contacting the work object, and is configured such that an operator who operates the robot perceives a reaction force received by the construction means from the work object.

[0011] (2) As an embodiment of the present disclosure, in (1), The robot includes a master robot operated by the operator and a slave robot that performs a predetermined operation on the work object. The construction means applies centrifugal force to the work object, and the slave robot outputs a reaction force command value according to the reaction force received from the work object of the construction means, and the master robot is configured to generate a reaction force that allows the operator to perceive based on the reaction force command value.

[0012] (3) As one embodiment of the present disclosure, in (1) or (2), the robot is provided with control means for controlling a motor by synthesizing control target values of position, velocity, and force for the work object at an arbitrary ratio.

[0013] (4) As one embodiment of the present disclosure, in any one of (1) to (3), the construction means applies centrifugal force to at least one of the side surface and the upper surface of the work object.

[0014] (5) As one embodiment of the present disclosure, in any one of (1) to (4), the weight of the shaped refractory is 30 kg / unit or more.

Advantages of the Invention

[0015] According to the present disclosure, it is possible to provide a remote operation system that can utilize the skills of a furnace builder and shorten the time required for construction.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

MODE FOR CARRYING OUT THE INVENTION

[0017] Hereinafter, a remote operation system according to an embodiment of the present disclosure will be described with reference to the drawings. In each figure, the same or corresponding parts are denoted by the same reference numerals. In the description of this embodiment, the description of the same or corresponding parts will be omitted or simplified as appropriate.

[0018] FIG. 1 schematically shows a cross section of a shaped refractory 101 constructed in a kiln 1. The kiln 1 is a refining vessel such as a converter or a torpedo car, for example. The kiln 1 is composed of an iron skin 11 and a shaped refractory 101. The shaped refractory 101 is constructed by stacking in a plurality of stages in the height direction inside the kiln 1 with respect to the iron skin 11. The shaped refractory 101 includes a permanent brick 12 and a wear brick 13. Each of the permanent brick 12 and the wear brick 13 may be of one type or a plurality of types. The permanent brick 12 and the wear brick 13 are adhered by an unshaped refractory 14. The remote operation system according to this embodiment constructs refractories including the shaped refractory 101 and the unshaped refractory 14. Here, the direction perpendicular to the height direction and from the inside to the outside of the kiln 1 may be referred to as the depth direction. Each of the permanent brick 12 and the wear brick 13 may form one layer or a plurality of layers in the depth direction. Although, for example, mortar is used as the unshaped refractory 14, the unshaped refractory 14 is not limited thereto and may be a stamp material, dry powder, or the like.

[0019] Further, the kiln 1 is cylindrical. FIG. 2 is a diagram schematically showing a cross-section of the kiln 1 in a plane perpendicular to the height direction. When the line-of-sight direction for viewing the kiln 1 is the height direction, the cross-section of the kiln 1 has a circular shape. Hereinafter, the cross-section of the kiln 1 shown in FIG. 2 may be referred to as a horizontal cross-section. Here, the circle may be a perfect circle or an ellipse. Also, for example, a state in which the iron sheet 11 has irregularities so as to protrude in the depth positive direction or the depth negative direction in the horizontal cross-section of the kiln 1 or a state in which the curvature of the iron sheet 11 is partially different in the horizontal cross-section of the kiln 1 is also included in the cylindrical shape described in this specification. That is, the cylindrical shape in this specification includes a shape in which the horizontal cross-section is generally circular (i.e., a substantially cylindrical shape).

[0020] FIG. 3 is an enlarged view of the wear brick 13. The numerical values (unit: mm) described are examples and are not limited to these values. The left figure of FIG. 3 shows the side surface of the wear brick 13. The right figure of FIG. 3 shows the upper surface of the wear brick 13. The wider side (162.5 mm in the right figure of FIG. 3) is arranged so as to be closer to the iron sheet 11 in the depth direction. That is, a taper is provided such that the side of the iron sheet 11 is large and the side inside the furnace is small. Here, the inside of the furnace means the inside of a container such as a converter, that is, the inside of the kiln 1. As described above, the kiln 1 is cylindrical and the size of the furnace also varies. Also, the regular refractory 101 is a three-dimensional object composed of a plane instead of a curved surface. Therefore, when the regular refractory 101 is constructed along the circle that is the cross-section of the kiln 1, a gap is generated between adjacent regular refractories 101. The remote operation system according to the present embodiment is a remote operation system for construction in which the regular refractory 101 that generates a gap with the adjacent one is constructed in the cylindrical kiln 1.

[0021] Referring to FIG. 1 again, in the present embodiment, the regular refractory 101 is constructed using the robot 17. Also, the measuring instrument 16 is used in the construction.

[0022] Robot 17 is equipped with means for installing standardized refractory 101 and performs predetermined operations on the object to be worked on. The object to be worked on refers to the standardized refractory 101 that Robot 17 is installing. When the installation work of one standardized refractory 101 as the object to be worked on is completed, Robot 17 changes the object to be worked on to the next standardized refractory 101. Robot 17 is, for example, a robot arm (manipulator), but is not limited to a robot arm. Also, the installation means is not particularly limited as long as it can grip the standardized refractory 101, stack the standardized refractory 101, apply unshaped refractory 14 to the standardized refractory 101, and apply stress to the standardized refractory 101. Generally, when installing the standardized refractory 101, an "attachment and spreading operation" of pre-applying the unshaped refractory 14 to the standardized refractory 101 to be installed next is performed. However, it is not limited to this, and a "laying and spreading operation" of pre-applying the unshaped refractory 14 to the already installed standardized refractory 101 may be performed. In the present embodiment, Robot 17 is equipped with a hammer as part of the installation means. Robot 17 has a function of being able to adjust the position of the brick by hitting the side surface, upper surface, etc. of the brick using the hammer. The hammer comes into direct contact with the object to be worked on. Also, the hammer is provided on the rotating part of Robot 17 to apply centrifugal force to the object to be worked on. For example, the hammer applies centrifugal force to at least one of the side surface and the upper surface of the object to be worked on for adjusting the position of the object to be worked on.

[0023] Robot 17 may be, for example, a 6-axis vertical articulated robot. As the robot hand (an example of the installation means), a two-finger gripping hand or a six-point suction hand may be used. When gripping the standardized refractory 101, rubber packings or the like may be used on the finger parts so that the standardized refractory 101 is not damaged. The size of Robot 17 may be selected according to the size of the kiln 1 and the weight of the standardized refractory 101 to be gripped.

[0024] The robot 17 may be operated by a controller, for example, by an operator on the machine side. Further, the robot 17 may include, for example, a master robot operated by an operator and a slave robot that performs a predetermined operation on a work object. The slave robot may have a function of sensing a reaction force generated when the standard refractory 101 is constructed. A reaction force command value may be output according to the reaction force sensed by the slave robot, and the master robot may generate a reaction force that is made perceptible to the operator based on the reaction force command value.

[0025] The robot 17 may be provided with control means for controlling a motor by synthesizing control target values of position, speed, and force for the standard refractory 101, which is a work object, at an arbitrary ratio. The control means may be realized by an arithmetic device such as a processor. By controlling the motor in this way, it is possible to prevent damage to the bricks when constructing the bricks. Also, it is possible to reproduce delicate movements like those of a skilled bricklayer.

[0026] Here, the weight of one of the standard refractories 101 is often less than 30 kg so that it is easy for a bricklayer to construct. However, in the method for constructing the standard refractory 101 according to the present embodiment, there is no limit on the weight because the robot 17 performs the construction. That is, the weight of the standard refractory 101 may be 30 kg / unit or more. Here, the size of the standard refractory 101 may be determined according to the damage factor of the container. For example, in a container where chemical damage is the main factor and cracks caused by thermal stress do not occur, by using a large standard refractory 101, it is possible to reduce wear due to melting loss at the joint portion.

[0027] The measuring device 16 measures the inside of the furnace. In the present embodiment, the measuring device 16 performs in-furnace measurement for grasping the construction state inside the furnace and the like. Further, the measuring device 16 measures the position of the work object. By measuring the position of the work object, the gap between the adjacent standard refractory bricks 101 that have been constructed can be grasped. The measuring device 16 may be a laser-type or white light interference-type measuring device. Further, when the operator remotely operates the robot 17, the operation can be performed based on the visual information (for example, an image) from the measuring device 16. In the present embodiment, the measuring device 16 includes a camera. The camera may be a general imaging camera or a 3D camera capable of obtaining depth information. The measuring method of the measuring device 16 can be selected from a stereo method of taking pictures using a plurality of cameras, a ToF method of calculating the time when the reflected light returns using pulsed light, a method using structured illumination using light interference, and the like.

[0028] In the present embodiment, the operator is a bricklayer, and can perceive the reaction force by the configuration of the master robot and the slave robot described above. The bricklayer can perform construction with an appropriate force according to the perceived reaction force, and can prevent brick breakage. Since the bricklayer can perform the operation based on the visual information from the measuring device 16, the position of the work object and the gap between the adjacent standard refractory bricks 101 that have been constructed can be grasped, and it can be easily determined whether it is appropriate. Further, the bricklayer can perform construction using, for example, heavy standard refractory bricks 101 of 30 kg / each or more by remotely operating the robot 17. Therefore, by the remote operation system according to the present embodiment, the skills of the bricklayer can be utilized, and the time required for construction (bricklaying) can be shortened.

[0029] FIG. 4 is a schematic diagram for explaining construction by the remote operation system according to the present embodiment. The ware bricks 13 shown in FIG. 4 are arranged in the horizontal cross section of the kiln 1 in the same manner as in FIG. 2, showing the state during construction. The ware bricks 13, also denoted as 13A in FIG. 4, indicate the object to be worked on by the robot 17. As shown by P in FIG. 4, if the arrangement of the standard refractory 101 is displaced due to deformation on the iron skin 11 side, etc., it affects the shape of the gap S. For example, as in the left diagram of FIG. 4, in the temporary installation of the object to be worked on, due to the influence of the deformation on the iron skin 11 side, the gap S is larger than the gap between the already constructed standard refractories 101. If construction continues with the shape of the gap S being significantly different from others, problems such as the object to be worked on being likely to fall off due to the influence of "seri" will occur. In the construction using the remote operation system according to the present embodiment, the position of the object to be worked on and the shape of the gap S are measured by the measuring instrument 16.

[0030] When constructing according to the shape of the standard refractory 101, in the case of the shape of the iron skin 11 where the gap becomes larger on the back side (the positive direction of the depth), the back of the standard refractory 101 will be filled with the unshaped refractory 14. However, the thickness of the unshaped refractory 14 increases and it shrinks significantly due to thermal stress during operation. By shrinking, the standard refractory 101 may move to the back side and a rotational force may act. The adjacent standard refractory 101 in contact with the standard refractory 101 that has moved to the back side receives a vertical stress from the standard refractory 101 that has moved to the back side. Depending on the positional relationship of these standard refractories 101, a vertical stress may be applied to the adjacent standard refractory 101 toward the inside of the furnace (the negative direction of the depth). Applying a vertical stress toward the inside of the furnace to the adjacent standard refractory 101 can be prevented by constructing the unshaped refractory 14 with a high viscosity on the back side and adjusting the gap between the standard refractory 101 with a large gap on the back side and the adjacent standard refractory 101. The unshaped refractory 14 on the back side is preferably further of high strength and low shrinkage. FIG. 6 is a diagram illustrating the adjustment of the gap. In the example of FIG. 6, even if the gaps between the three standard refractories 101 are not the same and the unshaped refractory 14 on the back of the central standard refractory 101 thermally shrinks, the gap is adjusted so that no force in the dropping direction is applied.

[0031] The furnace builder, who is the operator, can adjust the position of the work object by remote operation using the robot 17 based on the visual information from the measuring instrument 16. Here, it is assumed that the robot 17 includes a master robot operated by the operator and a slave robot that performs adjustment work on the work object. Further, in the robot 17, a hammer is provided at the tip of the slave robot as part of the construction means. As shown in the right figure of FIG. 4, the construction means (hammer) applies a centrifugal force to the work object to adjust the position of the work object. In this case, the operator operating the master robot perceives the reaction force received by the hammer from the work object. Specifically described, the slave robot measures the reaction force received from the work object of the hammer, outputs a reaction force command value according to the measured reaction force, and the master robot generates a reaction force that allows the operator to perceive based on the reaction force command value. The operator can adjust the strength of the centrifugal force applied to the work object or change the surface (side surface or upper surface) to strike the work object according to the perceived reaction force. In the prior art, it was not possible to perform construction considering the influence of the deformation on the iron sheet 11 side. In the remote operation system according to the present embodiment, while being a remote operation, the operator (furnace builder) can grasp the position and reaction force of the work object, can utilize the skills of the furnace builder, and can shorten the time required for construction.

[0032] FIG. 5 is a flowchart showing the process of the method for constructing the standard refractory 101 using the remote operation system according to the present embodiment.

[0033] First, in-furnace measurement is executed by the measuring instrument 16 (step S1). Here, when it is not necessary to check the state inside the furnace, step S1 can be omitted.

[0034] Next, the work object is temporarily installed by the robot 17 (step S2). For example, the operator operates the master robot, grips the standard refractory 101, which is the work object, with the robot hand of the slave robot, and performs an operation of placing it at the installation location while visually checking the position of the work object.

[0035] The position of the temporarily set object to be worked on is adjusted by the working means of the robot 17 (step S3). The working means of the robot 17 used for the adjustment is specifically a hammer. The operator operates the robot 17 to adjust the position of the object to be worked on so that the shape of the gap S (see FIG. 4) is aligned with others.

[0036] The reaction force from the object to be worked on and the position of the object to be worked on are measured (step S4) and fed back to the operator. As described above, the operator can adjust the strength of the centrifugal force acting on the object to be worked on or change the surface to strike the object to be worked on according to the perceived reaction force. Also, the operator can operate the robot 17 while checking the state of the gap based on the visual information from the measuring instrument 16.

[0037] If the position of the object to be worked on is not appropriate (No in step S5), the process returns to the process of step S3 and the position is adjusted again by the hammer. If the position of the object to be worked on is appropriate (Yes in step S5), it is confirmed whether the installed object to be worked on is the last one (step S6).

[0038] If the installed object to be worked on is the last one (Yes in step S6), the series of processes is terminated. If the installed object to be worked on is not the last one (No in step S6), the object to be worked on is changed (step S7). That is, another standard refractory 101 is set as the new object to be worked on. Then, the process returns to step S1 and the process continues.

[0039] As described above, the remote operation system according to the present embodiment can utilize the skills of a furnace builder and shorten the time required for construction with the above configuration.

[0040] Although the embodiments according to the present disclosure have been described based on the various drawings and examples, it should be noted that those skilled in the art can easily make various deformations or modifications based on the present disclosure. Therefore, it should be noted that these deformations or modifications are included in the scope of the present disclosure.

[0041] For example, as a simple method, it can be constructed using a hand lifter as the robot 17. In this case, the operator feels the reaction force signal received by the hand lifter and performs the work. Also, when the robot 17 is composed of an operation side (for example, a master robot or a controller) and a manipulator side (for example, a slave robot), the operation side and the manipulator side may be similar in shape. When they are similar in shape, it becomes easier for the operator to remotely operate, but it is not essential to be configured in a similar shape. Further, the installation method of the manipulator side is not limited, and for example, it may be provided so as to be suspended from the upper part of the kiln 1, or may be provided on a cart that can move freely.

[0042] In the above embodiment, an example where the weight of the standard refractory 101 is 30 kg or more per piece has been described, but a heavier standard refractory 101 may be used. For example, bricks weighing 100 kg each can also be constructed.

[0043] In the above embodiment, the number and position of the measuring instrument 16 are not limited. For example, the number of the measuring instruments 16 may be one, or may be two or more. For example, a first measuring instrument 16 capable of measuring the entire inside of the furnace from above in the height direction is installed, and a second measuring instrument 16 capable of measuring the area including the work object on the robot 17 is installed and used in combination. Here, it is preferable to prevent the area to be measured from being in the shadow. The second measuring instrument 16 may be installed, for example, at a position about 0.5 m above and about 0.7 m horizontally away from the construction means.

Explanation of Reference Numerals

[0044] 1 Kiln 11 Iron sheet 12 Permanent brick 13 Wear brick 14 Refractory mortar 16 Measuring instrument 17 Robot 101 Standard refractory

Claims

1. A remote operation system for constructing refractories including shaped refractories and unshaped refractories in a cylindrical kiln, comprising: a robot that uses the shaped refractory as a work object and performs a predetermined operation on the work object; a measuring instrument that measures the position of the work object; construction means provided on the robot and contacting the work object; and an operator who operates the robot grasps a gap between the constructed adjacent shaped refractories based on visual information including the position of the work object measured by the measuring instrument, and the construction means is configured to perceive a reaction force received from the work object; the robot includes a master robot operated by the operator and a slave robot that performs a predetermined operation on the work object; the construction means applies a centrifugal force to the work object, the slave robot outputs a reaction force command value according to the reaction force received from the work object by the construction means, and the master robot is configured to generate a reaction force that allows the operator to perceive based on the reaction force command value. A remote operation system.

2. The remote operation system according to claim 1, wherein the robot includes control means for synthesizing control target values of position, speed, and force for the work object at an arbitrary ratio and controlling a motor.

3. The remote operation system according to claim 1 or 2, wherein the construction means applies a centrifugal force to at least one of a side surface and an upper surface of the work object.

4. The remote operation system according to claim 3, wherein the weight of the shaped refractory is 30 kg or more per piece.

5. A remote operation system for constructing refractories including shaped refractories and unshaped refractories in a cylindrical kiln, comprising: a robot that uses the shaped refractory as a work object and performs a predetermined operation on the work object; a measuring instrument that measures the position of the work object; construction means provided on the robot and contacting the work object; and an operator who operates the robot grasps a gap between the constructed adjacent shaped refractories based on visual information including the position of the work object measured by the measuring instrument, and the construction means is configured to perceive a reaction force received from the work object; the construction means applies a centrifugal force to at least one of a side surface and an upper surface of the work object. A remote operation system.

6. The remote operation system according to claim 5, wherein the weight of the shaped refractory is 30 kg or more per piece.

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