Repair system and repair method

Abstract

To execute the repair of a refractory layer at high precision without executing spraying or the installation of a core.SOLUTION: Provided is a repair system for a structure having a refractory layer on an inner face. The repair system comprises: a measurement device for measuring a three-dimensional shape of the inner face in the structure; a removal device for removing at least a part of the refractory layer on the inner face of the structure; a molding device for lamination-molding a refractory block fitted to the inner face of the structure after the removal of the at least a part of the refractory layer by the removal device using an unshaped refractory; a molding control device for controlling the molding device based on the measurement result by the measurement device; and an installation device for fitting the refractory block to the inner face of the structure.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a system for repairing a structure having a refractory layer on its inner surface, and also to a method for repairing a structure having a refractory layer on its inner surface. [Background technology]

[0002] Structures for holding high-temperature contents generally have a refractory layer provided on the inner surface of the structure as a lining to protect the structure from the heat of the contents. Examples of structures having such a refractory layer include containers for holding molten metal (hereinafter referred to as "molten metal containers") and molten metal troughs such as blast furnace troughs.

[0003] However, when such a structure is used, the refractory layer gradually deteriorates due to wear caused by contact with the high-temperature contents and spalling (cracks and peeling) caused by thermal shock, etc. Therefore, to maintain the functionality of the refractory layer, it is necessary to carry out periodic repairs.

[0004] A commonly used method for repairing a refractory layer is to spray a monolithic refractory. However, when a monolithic refractory is sprayed onto a deteriorated refractory layer, an interface between the deteriorated refractory layer and a new refractory layer remains inside the repaired refractory layer. In addition, molten metal, slag, and other debris (also known as slag or buildup) that adhered during the use of the structure may adhere to the surface of the deteriorated refractory layer. Therefore, if cracks occur in the new refractory layer on the surface side during use of the structure after repair, molten metal and other debris may penetrate through the cracks to the interface between the deteriorated refractory layer and the new refractory layer, causing the new refractory layer to peel off.

[0005] Therefore, in order to prevent the above-mentioned peeling, when repairing a refractory layer, the surface of the area to be repaired is scraped to remove the deteriorated refractory layer and any slag adhering to the surface of the refractory layer, and then unshaped refractory material is sprayed on.

[0006] For example, Patent Document 1 describes that when repairing the lining inside a molten metal structure by spraying, the deteriorated layer on the surface of the refractory layer is first removed and dismantled over the entire surface using a crushing tool. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-292278 Summary of the Invention [Problem to be solved by the invention]

[0008] As described in Patent Document 1, peeling of the new refractory layer can be prevented by removing a deteriorated layer on the surface of the refractory layer beforehand and then spraying.

[0009] However, repairing a refractory layer by spraying is usually performed by an operator holding a spray nozzle by hand and discharging a monolithic refractory from the nozzle. This makes it difficult to achieve a uniform final thickness for the refractory layer. Even if spraying can be performed to achieve a flat surface, it is difficult to confirm whether a refractory layer of the desired thickness has been formed. Furthermore, there is also the problem that continuously spraying a heavy monolithic refractory while holding the nozzle places a heavy burden on the operator.

[0010] Also known is a method of applying a monolithic refractory layer by pouring instead of spraying. In this method, a mold called a core is placed inside the structure, and the monolithic refractory is poured into the space between the inner surface of the structure and the core, and then hardened to form a refractory layer.

[0011] However, in the pouring method, the shape and dimensions of the core are fixed, so it is not possible to adapt to the shape of the structure that changes during operation. Therefore, it is difficult to make the final thickness of the refractory uniform. It is also difficult to accurately position the core in the limited space inside the structure.

[0012] The present invention has been made in consideration of the above circumstances, and aims to provide a repair system and repair method that are capable of repairing a refractory layer with high precision without spraying or installing a core. [Means for solving the problem]

[0013] The present invention has been made to solve the above problems, and the gist and configuration of the present invention are as follows.

[0014] 1. A repair system for a structure having a refractory layer on its inner surface, a measuring device for measuring the three-dimensional shape of the inner surface of the structure; a removal device for removing at least a portion of the refractory layer on the inner surface of the structure; a molding device that uses monolithic refractory to layer-by-layer manufacturing to form a refractory block that fits onto the inner surface of the structure after at least a portion of the refractory layer has been removed by the removal device; a molding control device that controls the molding device based on the measurement result by the measuring device; and an installation device that installs the refractory block in a position that fits onto the inner surface of the structure.

[0015] 2. The measuring device measures the three-dimensional shape of the inner surface of the structure after the refractory layer has been removed by the removing device, The repair system described in 1 above, wherein the molding control device controls the molding device based on the results of the measurement.

[0016] 3. The measuring device measures the three-dimensional shape of the inner surface of the structure before the refractory layer is removed by the removing device, The repair system described in 1 above, wherein the shaping control device calculates the three-dimensional shape of the inner surface of the structure after the refractory layer has been removed by the removal device by subtracting the portion actually removed by the removal device from the three-dimensional shape obtained by the measurement, and controls the shaping device based on the calculated three-dimensional shape.

[0017] 4. A method for repairing a structure having a refractory layer on its inner surface, comprising: a measuring step of measuring a three-dimensional shape of the inner surface of the structure; a removing step of removing at least a portion of the refractory layer on the inner surface of the structure; a manufacturing process of layer-by-layer manufacturing a refractory block that fits onto the inner surface of the structure after at least a portion of the refractory layer has been removed in the removing process, using a monolithic refractory; and an installation step of installing the refractory block at a position where the refractory block fits into the inner surface of the structure, A repair method, wherein in the forming step, forming is controlled based on the measurement results in the measuring step.

[0018] 5. In the measuring step, the three-dimensional shape of the inner surface of the structure after the refractory layer has been removed in the removing step is measured; 5. The repair method according to claim 4, wherein in the shaping step, the shaping is controlled based on the results of the measurement.

[0019] 6. In the measuring step, the three-dimensional shape of the inner surface of the structure before the refractory layer is removed in the removing step is measured; 5. A repair method as described in 4 above, wherein in the shaping process, the three-dimensional shape of the inner surface of the structure after the refractory layer has been removed in the removal process is calculated by subtracting the portion actually removed in the removal process from the three-dimensional shape obtained by the measurement, and the shaping is controlled based on the calculated three-dimensional shape. [Effects of the Invention]

[0020] According to the present invention, the refractory layer can be repaired with high precision without spraying or installing a core. DETAILED DESCRIPTION OF THE INVENTION

[0021] Hereinafter, examples of embodiments of the present invention will be specifically described. Note that the following description is merely illustrative of embodiments of the present invention, and the present invention is not limited to the following embodiments.

[0022] [Structure] The present invention is directed to repairing a structure having a refractory layer on its inner surface. The structure may be any structure having a refractory layer at least on its inner surface. The structure may be, for example, a structure for molten metal. Examples of the structure for molten metal include molten metal vessels such as hot metal ladles, molten steel ladles, and refining vessels, and molten metal troughs such as blast furnace troughs.

[0023] The present invention can be applied to a refractory layer having any material and structure, and therefore the refractory layer provided on the inner surface of the structure may be made of any material and have any structure as long as it is a layer made of a refractory material.

[0024] It is also common for the lining refractory layer to be composed of a layer of standard refractory material called "perm bricks" and a layer of monolithic refractory material. For example, a typical molten metal structure includes a metal structure body called a steel shell, a layer of standard refractory material (perm bricks) provided on the inner surface of the metal structure body, and a layer of monolithic refractory material provided on the inner surface of the standard refractory layer, and the refractory layer is composed of the standard refractory layer and the monolithic refractory layer. The present invention can also be suitably used for repairing a refractory layer having the above-mentioned structure.

[0025] The present invention will be described below based on specific embodiments. Note that in the following embodiments, the structure is mainly described as a container, but as mentioned above, the present invention is not limited to a container and can be applied to any structure.

[0026] A repair system according to one embodiment of the present invention includes the following (1) to (5). (1) A measuring device for measuring the three-dimensional shape of the interior of a structure (2) A removal device for removing at least a portion of the refractory layer on the inner surface of the structure. (3) A manufacturing device that uses monolithic refractory to create refractory blocks that fit inside the structure. (4) a molding control device that controls the molding device based on the measurement results of the measurement device; (5) An installation device for installing the refractory block in a position where it fits into the inner surface of the structure.

[0027] Furthermore, a repair method according to another first embodiment of the present invention includes the following steps (A) to (D), and in the (C) shaping step, shaping is controlled based on the measurement results in the (A) measuring step. (A) Measurement process for measuring the 3D shape of the inner surface of a structure (B) A removal step of removing at least a part of the refractory layer on the inner surface of the structure. (C) A manufacturing process in which refractory blocks that fit into the inner surface of the structure are manufactured by layering using monolithic refractory. (D) an installation step of installing the refractory block in a position where it fits into the inner surface of the structure;

[0028] Each of the above-mentioned devices and steps will be described below.

[0029] [measurement] In the present invention, it is important to measure the three-dimensional shape of the inner surface of the structure and control the molding device based on the results, which allows the refractory block to be molded to match the actual shape of the inner surface of the structure.

[0030] The measuring device used to measure the three-dimensional shape is not particularly limited, and any device can be used as long as it can measure the three-dimensional shape of the inner surface of a structure. Suitable measuring devices include, for example, a three-dimensional laser scanner, a photogrammetry-based three-dimensional shape measuring device, and a pattern projection-based three-dimensional shape measuring device, and among these, it is preferable to use a three-dimensional laser scanner.

[0031] The measurement of the three-dimensional shape may be performed once or multiple times. If the entire measurement range fits within the field of view of the measuring device used, three-dimensional shape data of the entire structure can be obtained in a single measurement. For example, if the structure is a container, a three-dimensional laser scanner is placed on the central axis of the container at the height of the container's mouth, and a 360° laser scan is performed around the central axis of the container, thereby obtaining the three-dimensional shape of the container's inner surface in a single measurement. On the other hand, when performing measurements using photogrammetry, the measurement range is limited to the camera's field of view due to the measurement principle. Therefore, the inner surface of the structure can be measured multiple times while changing the orientation and position of the measuring device (camera), and the data can be combined in post-processing to obtain three-dimensional shape data of the entire inner surface of the structure.

[0032] The measuring device can also be installed in the facility that uses the structure to be repaired. For example, if the structure is a container (ladle) for transporting molten steel in a steelworks, the three-dimensional shape of the container's inner surface can be measured using a measuring device installed in the facility every time the container is used for one charge. Note that "charge" here refers to the cycle from receiving molten metal from a converter or the like into the container, passing through a secondary refining process to remove impurities from the molten steel, and then sending the molten metal to the next process, such as a casting facility, until the container is emptied.

[0033] The timing for measuring the three-dimensional shape of the inner surface of the structure by the measuring device is not particularly limited, but it is preferable to perform the measurement at least either before or after the removal of the refractory layer by the removal device. The timing of the measurement will be explained further below.

[0034] Remove Next, at least a portion of the refractory layer on the inner surface of the structure is removed. Any device can be used for the removal, without any particular limitations, as long as it can remove standard refractory. Typically, the removal device preferably includes a tool that cuts, crushes, or peels off the refractory layer with a rotating or reciprocating tool. Furthermore, in order to perform the removal while scanning the tool along the inner surface of the vessel, the removal device preferably includes a moving means for moving the tool three-dimensionally and an attitude control means for controlling the attitude (direction) of the tool. The moving means and attitude control means can be, for example, an arm of heavy machinery. The heavy machinery preferably includes, for example, a vehicle body driven by caterpillars or the like and an arm that can position the tool with six or more degrees of freedom (position / rotation in three axial directions).

[0035] The removal can be performed by any method. However, if a new refractory block is installed while slag or a deteriorated refractory layer remains, sufficient adhesion may not be obtained. For example, if the structure is a molten metal container, pouring high-temperature molten metal into the repaired container may melt the remaining slag due to the heat, resulting in the peeling off of the installed refractory block. Therefore, in the removal, it is preferable to remove at least the slag adhering to the surface of the refractory layer on the inner surface of the structure and the deteriorated portion (deteriorated layer) on the surface side of the refractory layer.

[0036] When removing the material by scanning the tool along the inner surface of the container, the scanning pattern is not particularly limited and may be determined according to the removal device to be used and the shape of the container to be removed. Considering that the cutting powder falls downward, it is preferable to repeat the operation of removing the material by scanning the inner surface of the container in the circumferential direction from bottom to top.

[0037] Furthermore, when removal is performed by scanning the tool along the inner surface of the container, removal can be performed in one scan (one pass), but removal can also be performed in multiple scans (multiple passes). When removal is performed in multiple passes, the number of scans can be any number greater than or equal to two, but an excessively large number of scans will increase the time required for removal and reduce work efficiency. Therefore, it is preferable to limit the number of scans to three or less. Furthermore, when removal is performed in multiple passes, the amount of removal in the next scan can be calculated after one scan is completed.

[0038] [molding] In the present invention, a refractory block that fits onto the inner surface of the structure after at least a portion of the refractory layer has been removed by the removal device is additively manufactured using monolithic refractory. By installing the additively manufactured refractory block at a position where it will fit onto the inner surface of the structure in the subsequent installation step, accurate repair can be performed without spraying or pouring using a core.

[0039] The additive manufacturing can be carried out at any location without any particular limitations, but typically it is preferably carried out outside the structure to be repaired.

[0040] The additive manufacturing method is not particularly limited, and any device can be used as long as it can laminate monolithic refractory to produce a refractory block of a desired three-dimensional shape. Typically, the molding device preferably includes a tank for holding the monolithic refractory, a nozzle for discharging the monolithic refractory, and a pump for feeding the monolithic refractory from the tank to the nozzle. The molding device preferably includes a nozzle moving means for moving the nozzle three-dimensionally and a nozzle attitude control means for controlling the attitude (orientation) of the nozzle. The nozzle moving means and the nozzle attitude control means preferably include, for example, a gate-shaped traveling carriage that can run on a traveling rail installed on a work floor, a traverse carriage that travels on a traverse rail installed on the carriage in a direction perpendicular to the rail, a lifting carriage that moves on a lifting rail installed on the traverse carriage, and an actuator for adjusting the nozzle discharge angle installed on the lifting carriage.

[0041] In the shaping, any monolithic refractory can be used without any particular limitation. As the monolithic refractory, a monolithic refractory used in conventional spraying or pouring construction can also be used. By changing the water content or composition of the monolithic refractory, the fluidity and hardening time of the monolithic refractory can be adjusted to facilitate additive manufacturing.

[0042] In the shaping step, the monolithic refractory may be hardened by drying. The drying may be natural drying, heat drying, or both. The refractory block may be completely dried, but it is sufficient to dry it at least to the extent that it can be transported and installed by installation equipment such as a crane.

[0043] In one embodiment of the present invention, drying and firing can be performed in the following manner. First, in the molding process, the refractory block produced by layer-by-layer molding is dried to a degree that allows transportation and installation. Next, the dried refractory block is installed in a position where it fits into the inner surface of the structure. Monolithic refractory is filled into the gaps between the existing refractory layer and the refractory block, and between the installed refractory blocks. Thereafter, the refractory block installed in the structure and the filled monolithic refractory are further heated to dry and fire.

[0044] The size of the refractory block is not particularly limited and can be any size. When a structure is large, if a refractory block that fits the entire inner surface of the structure is integrally formed, transportation and installation may be difficult. Therefore, taking into consideration ease of installation, it is preferable to create the refractory layer required for repair by dividing it into multiple blocks. For example, if the height of the repair target is 2 m or more, multiple refractory blocks each 1 m high can be created and installed sequentially from bottom to top to repair the entire structure. Furthermore, the refractory block may be divided into multiple blocks not only vertically but also horizontally. For example, when installing cylindrical refractory blocks on the inner surface of a container, the cylinder can be divided horizontally into 2 to 4 refractory blocks.

[0045] Furthermore, to prevent damage to the refractory block due to interference during fitting, it is preferable to provide a clearance when the refractory block is installed to fit with the structure. In other words, it is preferable to determine the size of the refractory block to be additively manufactured so that a clearance is provided when installed. The clearance is preferably at least one of (1) a gap between the surface of the structure after the deteriorated layer has been removed and the refractory block to be fitted thereto, and (2) a gap between the refractory blocks, and it is preferable to provide both.

[0046] However, if the repaired structure is operated with a gap (air layer) remaining in the clearance, molten metal or the like may enter the gap and melt the structure due to high temperatures. Therefore, after installing the refractory block, it is preferable to press-fit the monolithic refractory so that no air layer remains in the clearance. Therefore, it is preferable to form a sprue or runner in the refractory block for pressing the monolithic refractory into it.

[0047] [Modeling control] In the present invention, it is important to control the additive manufacturing process based on the measurement results obtained by the measuring device, thereby enabling the creation of a refractory block having a three-dimensional shape corresponding to the shape of the actual inner surface of the structure.

[0048] The specific control method is not particularly limited, but it is sufficient to refer to the three-dimensional shape data measured by the measuring device and control the operation of the molding device so that when the manufactured refractory block is installed, the inner surface of the structure will have the desired shape. Generally, it is preferable to extrude monolithic refractory from the nozzle tip of the molding device to form one layer of horizontal cross-sectional shape, and then stack these layers vertically one by one. In this control, various parameters that affect the three-dimensional shape of the final refractory layer, such as the nozzle scanning path, scanning speed, nozzle orientation, and extrusion amount, can be controlled. Furthermore, in this control, physical properties of the monolithic refractory, such as viscosity, can also be taken into consideration.

[0049] In the control, it is also preferable to use three-dimensional shape data (hereinafter referred to as target shape data) prepared in advance that represents a target shape. In other words, the target shape data is three-dimensional shape data that represents the shape of the inner surface of the structure after the refractory block manufactured by additive manufacturing is fitted to the inner surface of the structure. By comparing the three-dimensional shape data measured by a measuring device with the target shape data, it becomes possible to adjust the shape of the refractory block to be manufactured more accurately.

[0050] The target shape data can be prepared by any method. For example, the target shape data can be created from design data (CAD data, etc.) of a structure with a refractory layer formed thereon. Furthermore, for example, if the refractory layer is composed of a layer of standard refractory material known as perm bricks and a layer of monolithic refractory material, three-dimensional shape data for a state in which only the standard refractory layer is provided and no monolithic refractory layer is provided can be created from actual measurements or design data, and the target shape data can be created by calculating a shape obtained by adding a refractory layer of a desired thickness to the three-dimensional shape data.

[0051] Two preferred modes of the measurement and modeling control will be described below.

[0052] (Measurement method after removal) In one embodiment of the present invention, first, in the measuring step, the three-dimensional shape of the inner surface of the container after the refractory layer has been removed in the removing step is measured, and then, in the shaping step, shaping control is performed based on the measurement results (hereinafter referred to as a post-removal measurement method).

[0053] This post-removal measurement method allows for more accurate repairs because the 3D shape after removal is actually measured and control is based on the results. It is especially preferable to adopt the post-removal measurement method when considering the possibility that slag or deteriorated layers may not be removed as planned due to wear on the tools used for removal. Even if the 3D shape is measured before removal, it is possible to measure the 3D shape again after removal and use the measurement results.

[0054] (Measurement method before removal) In another embodiment of the present invention, the measuring step measures the three-dimensional shape of the inner surface of the vessel before the refractory layer is removed in the removing step. Then, in the shaping step, the portion actually removed in the removing step is subtracted from the three-dimensional shape obtained by the measurement to calculate the three-dimensional shape of the inner surface of the structure after the refractory layer has been removed in the removing step, and shaping control is performed based on the calculated three-dimensional shape (hereinafter referred to as the pre-removal measurement method).

[0055] In this pre-removal measurement method, the three-dimensional shape of the inner surface of the structure is measured before the refractory layer is removed in the removal process, and as will be described later, this pre-removal three-dimensional shape data can also be used to control the removal device in the removal process. In this case, it is only necessary to perform a single measurement before removal, and there is no need to measure the shape again after removal, resulting in high work efficiency.

[0056] As described above, according to the present invention, it is possible to form a refractory block having a three-dimensional shape corresponding to the shape of the inner surface of the structure after the refractory layer is removed.

[0057] [Installation] Next, the refractory block produced in the above-mentioned shaping process is installed in a position where it fits into the inner surface of the structure. The installation device for performing the installation is not particularly limited and any device can be used. A crane can typically be used as the installation device.

[0058] For example, a refractory block manufactured by additive manufacturing outside the structure can be loaded into the structure using a crane and installed at the desired position so as to fit into the inner surface of the structure.

[0059] After the refractory blocks are installed, it is preferable to press-fit monolithic refractories into the gaps. Specifically, it is preferable to fill the gaps between the existing refractory layer and the refractory blocks, and between the installed refractory blocks, with monolithic refractories.

[0060] It is preferable to further heat the structure after filling it with the monolithic refractory to dry and fire the installed refractory block and the filled monolithic refractory. The heating can be performed by any method. For example, a burner that sprays flames can be installed inside the structure to heat the inside of the structure to dry and fire it. In this case, if the structure is a container, it is preferable to cover the opening of the container to increase heating efficiency.

[0061] (Removal based on 3D shape data) In the present invention, the refractory layer can be removed by any method as described above, but in a more preferred embodiment of the present invention, the refractory layer can be removed based on the measurement results (three-dimensional shape data) obtained by performing measurement using the measuring device prior to the removal. The above embodiment will be described below.

[0062] The repair system in this embodiment further includes a calculation device that determines the area to remove the refractory layer based on the three-dimensional shape obtained by the measurement device, and the removal device is configured to remove the refractory layer on the inner surface of the structure based on the calculation result by the calculation device.

[0063] In addition, the repair method in this embodiment includes a calculation step for determining the range of the refractory layer to be removed based on the three-dimensional shape obtained in the measurement step, and in the removal step, the refractory layer on the inner surface of the structure is removed based on the calculation results in the calculation step.

[0064] [Calculation device / calculation process] In the above calculation, the extent of the refractory layer to be removed is determined based on the obtained three-dimensional shape of the inner surface of the structure. That is, since the three-dimensional shape of the inner surface of the structure is a surface profile including the refractory layer and the slag adhering to its surface, convex portions in the profile are likely to have thick slag attached thereto, and therefore, it can be determined that a larger amount of slag needs to be removed in those portions. Conversely, concave portions in the profile are likely to have become concave as a result of peeling of the deteriorated refractory layer, and therefore, it is sufficient to reduce the amount of refractory layer to be removed in those portions. In other words, it is preferable to determine the amount of refractory layer to be removed in each portion based on the obtained three-dimensional shape of the inner surface of the structure.

[0065] In addition, when determining the amount to be removed, information such as the usage history of the structure can also be taken into consideration. For example, if the three-dimensional shape of the inner surface of the structure is measured periodically, the occurrence of peeling can be determined based on the measurement data, and the peeled area can also be identified. Furthermore, if peeling does not occur, the approximate thickness of the deteriorated layer that will be formed can be estimated from the usage history of the structure (number of times used, usage time, etc.). Therefore, when determining the amount to be removed, the estimated thickness of the deteriorated layer estimated from the usage history of the structure can also be used. Furthermore, the thickness of the deteriorated layer that is formed tends to saturate at a certain level (e.g., 30 to 40 mm). Therefore, the known saturated thickness of the deteriorated layer can be input into a calculation device in advance and used to determine the amount to be removed.

[0066] In this way, by determining the area to be removed from the refractory layer based on the obtained three-dimensional shape of the inner surface of the structure, it is possible to more accurately remove slag and deteriorated layers adhering to the surface of the refractory layer and reduce the amount of undeteriorated refractory layer that is removed.

[0067] In the calculation step, it is also preferable to determine the range in which the refractory layer is to be removed, and to determine the scanning path of a tool used for removal so that the refractory layer in the determined range can be removed.

[0068] Furthermore, when determining the range of the refractory layer to be removed, it is also preferable to use three-dimensional shape data (hereinafter referred to as removal limit data) that indicates a removal limit position prepared in advance. Here, the removal limit position refers to a position beyond which (deeper than) removal should not be performed. By referring to the removal limit data when determining the range of the refractory layer to be removed, it is possible to prevent excessive removal of the refractory layer and damage to parts other than the refractory layer (such as the structure body) by the tool.

[0069] For example, as described above, when the refractory layer is composed of a layer of standard refractory called perm brick and a layer of monolithic refractory, it is preferable to remove only the layer of monolithic refractory and not the layer of standard refractory. Therefore, in such a case, by using the three-dimensional shape data of the state in which only the layer of standard refractory is provided and no layer of monolithic refractory is provided as the removal limit data, it is possible to prevent the layer of standard refractory from being removed.

[0070] As described above, the removal device may include the measuring device. When the removal device includes the measuring device, the measuring device can measure the three-dimensional shape of the inner surface of the structure, and the removal device can be controlled based on the results.

[0071] The removal device may also include a second measuring device, separate from the measuring device (here, referred to as the first measuring device), that measures the three-dimensional shape of the inner surface of the structure. When the removal device includes the second measuring device, the measurement results of the second measuring device can be used to align the removal device. For example, after the removal device is installed at a position where removal is to be performed, measurements can be performed using the second measuring device, and alignment can be easily performed by utilizing the results. As a more specific example, the three-dimensional shape of the inner surface of the structure can be measured using a first measuring device installed in a facility (such as a factory) that uses the structure to obtain first three-dimensional shape data, and then second three-dimensional shape data can be obtained using a second measuring device installed in the removal device. The first and second three-dimensional shape data can then be compared to align (determine the origin) the removal device. Examples of methods for comparing the first and second three-dimensional shape data include fitting one to the other. A coordinate transformation matrix between the coordinate system of the first three-dimensional shape data and the coordinate system of the second three-dimensional shape data can also be calculated.

[0072] The repair system in this embodiment may further include a control device that monitors the load on the removal device and adjusts the extent to which the refractory layer is removed based on the load.

[0073] The repair method of the present embodiment may further include a control step of monitoring the load in the removing step and adjusting the range of the refractory layer to be removed based on the load.

[0074] As mentioned above, slag may adhere to the surface of the refractory layer. However, because the refractory and slag are made of different materials, their physical properties (e.g., hardness) differ. Furthermore, even within the same refractory layer, the deteriorated portion (deteriorated layer) and the undeteriorated portion (healthy layer) have different physical properties. Therefore, by monitoring the load on the removal device during removal, changes in the physical properties of the portion currently being removed can be determined. Therefore, by adjusting the area of ​​the refractory layer to be removed based on the load, more accurate removal can be achieved.

[0075] The specific adjustment method is not particularly limited, but for example, a change in the part being removed (e.g., from slag to a deteriorated layer, or from a deteriorated layer to a healthy layer) can be detected based on a change in load, and a decision can be made to continue or end removal at that part based on that. As another example, an appropriate threshold can be set in advance, and by comparing the load with the threshold, it can be determined whether the part currently being removed is slag, a deteriorated layer, or a healthy layer, and a decision can be made to continue or end removal at that part based on that.

[0076] By making such adjustments, it becomes possible to remove slag and removal parts more accurately than when removal is performed based only on the measurement results of the three-dimensional shape, and it is also possible to further reduce the amount of undeteriorated refractory layer that is removed.

[0077] For example, if the process of removing material by scanning the tool in the depth direction at a constant cutting depth is repeated two or more times, the load value can be evaluated after each scan, and if it is determined that the healthy layer has been reached, subsequent passes can be omitted.

[0078] The load to be monitored can be any load that reflects changes in the physical properties of the part being removed. Typically, it is preferable to use the load applied to the actuator that drives the cutting tool. For example, if the cutting tool is rotated by a motor, the load applied to the motor can be monitored. If the motor is a hydraulic motor, the oil pressure can be monitored.

[0079] In addition, the repair system in this embodiment may further include a color information acquisition device that acquires color information of the inner surface of the structure, and the calculation device can determine the range of removal of the refractory layer by taking into account not only the three-dimensional shape obtained by the measurement means but also the color information obtained by the color information acquisition device.

[0080] In addition, the repair method in this embodiment may further include a color information acquisition process for acquiring color information of the inner surface of the structure, and in the calculation process, the range of the refractory layer to be removed can be determined by taking into account the color information obtained in the color information acquisition process in addition to the three-dimensional shape obtained in the measurement process.

[0081] As mentioned above, slag may adhere to the surface of a refractory layer. However, because the refractory and slag are made of different materials, their color tones differ. Furthermore, even within the same refractory layer, the deteriorated portion (deteriorated layer) and the undeteriorated portion (healthy layer) also have different color tones. For example, an undeteriorated healthy layer retains the original color of the refractory (typically light brown), whereas a deteriorated layer that has been degraded by contact with molten metal changes to a darker hue due to penetration by the metal. Therefore, by acquiring color information on the inner surface of a structure, the material of that portion can be determined. Therefore, when performing calculations to determine the area to remove the refractory layer, more accurate removal is possible by taking into account the color information in addition to the three-dimensional shape.

[0082] There are no particular limitations on how the color information is used, but it is preferable to set a threshold value in advance and compare the color information with the threshold value to determine whether the part in question is slag, a deteriorated layer, or a healthy layer.

[0083] The color information acquisition device can be any device capable of acquiring color information of the interior surface of a structure, but typically, a digital camera can be used. When a color information acquisition device is used, the color information acquisition device and a measuring device used to measure the three-dimensional shape can be separate or integrated. In other words, the measuring device used to measure the three-dimensional shape can also function as a color information acquisition device. For example, some laser scanners for measuring three-dimensional shapes have a built-in digital camera that captures color images and can map color information (RGB) to each point included in the three-dimensional point cloud data obtained by the laser scanner. Such a laser scanner with a built-in digital camera can be suitably used as a measuring device and color information acquisition device.

[0084] When using a color information acquisition device, the slag adhering to the inner surface of the structure can be removed in the first pass based on the measured 3D shape, and then color information can be acquired by the color information acquisition device, and based on the results, it can be determined whether the exposed surface is a deteriorated layer or a healthy layer. This allows the amount of removal in the second pass to be determined taking into account the judgment results based on the color information.

[0085] Next, a more preferred embodiment of the removal in the present invention will be described below.

[0086] (1) Measure the three-dimensional shape (shape 1) of the inner surface of the structure. (2) The scanning range is determined based on the three-dimensional shape obtained by the measurement, and the tool is scanned to remove the surface layer of the inner surface of the structure (first pass). (3) The three-dimensional shape (shape 2) of the inner surface of the structure after the removal is measured, and based on the difference between shape 1 and shape 2, it is determined which of the following states each part of the inner surface of the structure is in after the first pass of removal. A) The slag and deteriorated layer have peeled off together (the surface of the healthy layer is exposed). B) Surface where only the slag has peeled off (the surface of the deteriorated layer is exposed) C) There was no slag attached to the surface, but the deteriorated layer peeled off (exposing the surface of the healthy layer). D) There was no slag attached to the surface and no peeling occurred (the surface of the deteriorated layer is exposed). *Difference between shape 1 and shape 2: A>B>C>D *Degree of depression in shape 2: A≒C>B≒D Color information can also be used to determine whether the healthy layer is exposed. (4) Based on the above judgment results, the scanning range is determined, and the tool is scanned to remove the inner surface of the structure again (second pass). At this time, the exposed healthy layer is not removed.

Claims

1. A repair system for a structure having a refractory layer on its inner surface, comprising: a measuring device for measuring the three-dimensional shape of the inner surface of the structure; a removal device for removing at least a portion of the refractory layer on the inner surface of the structure; a molding device that uses monolithic refractory to layer-by-layer manufacturing to form a refractory block that fits onto the inner surface of the structure after at least a portion of the refractory layer has been removed by the removal device; a molding control device that controls the molding device based on the measurement result by the measuring device; an installation device that installs the refractory block at a position where it fits into the inner surface of the structure; the measuring device measures a three-dimensional shape of the inner surface of the structure before the refractory layer is removed by the removing device; The repair system, in which the shaping control device calculates the three-dimensional shape of the inner surface of the structure after the refractory layer has been removed by the removal device by subtracting the portion actually removed by the removal device from the three-dimensional shape obtained by the measurement, and controls the shaping device based on the calculated three-dimensional shape.

2. A method for repairing a structure having a refractory layer on its inner surface, comprising: a measuring step of measuring a three-dimensional shape of the inner surface of the structure; a removing step of removing at least a portion of the refractory layer on the inner surface of the structure; a manufacturing process of layer-by-layer manufacturing a refractory block that fits onto the inner surface of the structure after at least a portion of the refractory layer has been removed in the removing process, using a monolithic refractory; and an installation step of installing the refractory block at a position where the refractory block fits into the inner surface of the structure, In the modeling process, modeling is controlled based on the measurement result in the measuring process, In the measuring step, a three-dimensional shape of the inner surface of the structure before the refractory layer is removed in the removing step is measured; In the shaping process, the three-dimensional shape of the inner surface of the structure after the refractory layer has been removed in the removal process is calculated by subtracting the portion actually removed in the removal process from the three-dimensional shape obtained by the measurement, and the shaping is controlled based on the calculated three-dimensional shape.