Method and system for identifying the cause of an anomaly

Abstract

This invention provides a method for quickly identifying the cause of abnormalities that occur during the spray application of amorphous refractory materials. [Solution] Multiple state quantities related to the spraying of amorphous refractory materials are detected from multiple sensors, and when an abnormal value is detected among the values ​​obtained from the multiple sensors, the cause of the abnormal value is identified. To this end, a correspondence relationship is created in advance between the cause of the abnormal value and the detected values ​​of other state quantities excluding the state quantity detected as the abnormal value, and when an abnormal value is detected among the values ​​obtained from the multiple sensors, the cause of the abnormal value is identified based on the correspondence relationship.

Description

Technical Field

[0001] The present invention relates to a method and a system for identifying the causes of abnormalities occurring in the spraying construction of refractory castables.

Background Art

[0002] The spraying construction of refractory castables is a construction method in which the refractory castable is transported by compressed gas or the like and sprayed onto the construction target together with construction water, and can be roughly classified into wet spraying construction and dry spraying construction. Among these, the wet spraying construction is a construction method in which construction water is added to the spraying material in advance, kneaded into a slurry, and the refractory castable is pressure-fed, and a quick-setting material or the like is added at the spraying nozzle portion at the tip and sprayed (for example, Patent Document 1). On the other hand, the dry spraying construction is a construction method in which the refractory castable is pneumatically transported in a dry state, and construction water is injected at the spraying nozzle portion at the tip and sprayed (for example, Patent Document 2). Further, as an intermediate spraying construction between the wet spraying construction and the dry spraying construction, there is also a construction method in which water is injected in the transport path for transporting the spraying material (for example, Patent Document 3).

[0003] In any case, the spraying construction of refractory castables is a construction method in which the refractory castable is transported by compressed gas or the like and sprayed onto the construction target together with construction water. However, due to construction conditions such as the characteristics of the spraying material, the conditions of the construction target, and the ambient temperature, the amount of gas for transportation and the amount of added water vary, and in order to obtain a high-quality construction body, it is necessary to manage and confirm various construction conditions. Further, since the construction conditions always change, the constructor needs to adjust the construction conditions according to the situation.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

[0005] Traditionally, in the spray application of amorphous refractory materials, the management, verification, and adjustment of application conditions often relied on the experience and intuition of the contractor. For example, incorrect adjustments could lead to problems such as blockage of the spray material in the transport route or malfunction of the spraying equipment. However, because the history of the contractor's judgment, the content of the adjustments, and the changes in the state of the material due to those adjustments could not be quantitatively grasped, identifying the cause of the problem and subsequent recovery took a considerable amount of time.

[0006] The problem that this invention aims to solve is to provide a method and system for identifying the cause of an abnormality that can quickly identify the cause of an abnormality that occurs during the spraying of amorphous refractory materials. [Means for solving the problem]

[0007] According to one aspect of the present invention, the following method for identifying the cause of an abnormality is provided. An abnormality cause identification method that acquires detection values ​​of multiple state quantities related to the spraying of amorphous refractory materials from multiple sensors, and identifies the cause of an abnormal detection value when an abnormal detection value is detected among the detection values ​​acquired from the multiple sensors, In advance, a correspondence relationship is created between the cause of the abnormal detection value and the detection values ​​of other state quantities excluding the state quantity detected as the abnormal detection value. An abnormality cause identification method, which identifies the cause of an abnormal detection value based on the correspondence relationship when an abnormal detection value is detected among the detection values ​​obtained from the aforementioned multiple sensors.

[0008] According to another aspect of the present invention, the following abnormality cause identification system is provided. A detection value acquisition unit that acquires detection values ​​of multiple state quantities related to the spraying of unshaped refractory materials from multiple sensors, An abnormal cause identification system comprising: an abnormal cause identification unit that identifies the cause of an abnormal detected value when an abnormal detected value is detected in the detected values ​​acquired by the detected value acquisition unit, The abnormality cause identification unit is pre-programmed with the correspondence between the cause of the abnormal detected value and the detected values ​​of other state quantities, excluding the state quantity detected as the abnormal detected value. The abnormality cause identification unit identifies the cause of the abnormal detected value based on the correspondence relationship when it detects an abnormal detected value among the detected values ​​acquired by the detected value acquisition unit. [Effects of the Invention]

[0009] According to the present invention, the cause of any abnormalities that occur during the spraying of amorphous refractory materials can be quickly identified, and the abnormalities can be quickly corrected. [Brief explanation of the drawing]

[0010] [Figure 1] A conceptual diagram showing an example of the equipment configuration of a spray application device used for applying amorphous refractory materials. [Figure 2A] A conceptual diagram illustrating an example of the correspondence in this invention. [Figure 2B] A conceptual diagram illustrating another example of the correspondence in this invention. [Figure 2C] A conceptual diagram illustrating another example of the correspondence in this invention. [Figure 2D] A conceptual diagram illustrating another example of the correspondence in this invention. [Figure 3] A conceptual diagram showing the system configuration of the abnormal cause identification system according to the present invention. [Modes for carrying out the invention]

[0011] Figure 1 conceptually shows an example of the configuration of a spray application apparatus for applying amorphous refractory materials. The spray application apparatus X shown in the figure performs dry spray application and includes a transport gas introduction path 1 for introducing transport gas A, a material tank 2 connected to the downstream end of the transport gas introduction path 1, a material dispensing motor 3 for dispensing the spray material B stored in the material tank 2, a transport path (material hose) 4 for transporting the spray material B dispensed by the material dispensing motor 3 with transport gas A, a spray nozzle 5 connected to the downstream end of the transport path 4, and a water injection path 6 for injecting application water C into the spray nozzle 5. Here, a strainer 11, a pressure reducing valve 12, and a solenoid valve 13 are installed in the transport gas introduction path 1. A water injection pump 61 is installed in the water injection path 6. In the above configuration, the spray application device X transports the spray material B, which has been cut from the material tank 2 by the material cutting motor 3, through the transport path 4 to the spray nozzle 5 using transport gas A, and sprays it together with application water C from the tip (downstream end) of the spray nozzle 5 onto the application target.

[0012] The spray application device X, which performs the spray application of monolithic refractory materials in this manner, is equipped with multiple sensors to detect various state quantities related to the spray application of monolithic refractory materials. These will be explained in detail below. The conveying gas introduction path 1 is equipped with a pressure sensor 14 for detecting the supply pressure of conveying gas A (hereinafter referred to as "prime pressure"), a pressure sensor 15 for detecting the secondary pressure of the strainer 11, a pressure sensor 16 for detecting the secondary pressure of the pressure reducing valve 12, and a flow sensor 17 for detecting the flow rate of conveying gas A. The material tank 2 is equipped with a pressure sensor 21 that detects the pressure inside the material tank 2. The material cutting motor 3 is equipped with a power sensor 31 that detects the power consumption of the material cutting motor 3. The water injection path 6 is equipped with a pressure sensor 62 for detecting the pressure of the construction water C and a flow sensor 63 for detecting the flow rate of the construction water C.

[0013] In this embodiment, detection values of a plurality of state quantities related to the spraying construction of the monolithic refractory by the spraying construction device X are acquired from the plurality of sensors, and when an abnormal detection value is detected in the detection values acquired from the plurality of sensors, the cause of the abnormal detection value is specified. Specifically, in advance, a correspondence relationship is created between the cause of the abnormal detection value and the detection values of other state quantities excluding the state quantity detected as the abnormal detection value, and when an abnormal detection value is detected in the detection values acquired from the plurality of sensors, the cause of the abnormal detection value is specified based on the correspondence relationship.

[0014] FIG. 2A shows an example of the correspondence relationship. FIG. 2A shows the correspondence relationship between the cause of the occurrence and the detection values of other state quantities when an abnormal detection value (flow rate decrease) is detected in the detection value of the flow rate sensor 17 that detects the flow rate of the carrier gas A. For example, explaining the correspondence relationship along the uppermost row in FIG. 2A, when the detection value of the pressure sensor 21 that detects the pressure in the material tank 2 is lower than the specified value, the detection value of the pressure sensor 16 that detects the secondary side pressure of the pressure reducing valve 12 is lower than the specified value, and the detection value of the pressure sensor 14 that detects the original pressure of the carrier gas A is lower than the specified value, it means that the cause of the occurrence is a decrease in the supply amount of the carrier gas A.

[0015] FIG. 2B shows another example of the correspondence relationship. FIG. 2B shows the correspondence relationship between the cause of the occurrence and the detection values of other state quantities when an abnormal detection value (pressure decrease) is detected in the detection value of the pressure sensor 14 that detects the original pressure of the carrier gas A. For example, explaining the correspondence relationship along the second row from the top in FIG. 2B, when the detection value of the flow rate sensor 17 that detects the flow rate of the carrier gas A is higher than the specified value and the detection value of the pressure sensor 15 that detects the secondary side pressure of the strainer 11 is the specified value, it means that the cause of the occurrence is an abnormality in the pressure reducing valve 12.

[0016] Figure 2C shows another example of the above correspondence. Figure 2C shows the correspondence between the cause of an abnormal detection value (overload) when an abnormal detection value (overload) is detected in the power sensor 31 that detects the power consumption of the material cutting motor 3, and the detection values ​​of other state variables. For example, explaining the correspondence along the third row from the top in Figure 2C, if the detection value of the flow sensor 17 that detects the flow rate of the conveying gas A is lower than the specified value, the detection value of the pressure sensor 14 that detects the source pressure of the conveying gas A is at the specified value, and the detection value of the pressure sensor 15 that detects the secondary pressure of the strainer 11 is lower than the specified value, then the cause of the problem is clogging of the strainer 11.

[0017] Figure 2D shows another example of the above correspondence. Figure 2D shows the correspondence between the cause of an abnormal detection value (pressure rise) when an abnormal detection value (pressure rise) is detected by the pressure sensor 21 that detects the pressure in the material tank 2, and the detected values ​​of other state variables. For example, explaining the correspondence along the bottom row of Figure 2D, if the detection value of the flow sensor 17 that detects the flow rate of the transport gas A is at the specified value, and the detection value of the power sensor 31 that detects the power consumption of the material dispensing motor 3 is higher than the specified value, then the cause is a physical malfunction in the material tank 2.

[0018] In this embodiment, such correspondence relationships are created in advance based on past spray application experience, and when an abnormal detection value is detected in the detection values ​​obtained from the multiple sensors during actual spray application, the cause of the abnormal detection value is identified based on the above correspondence relationship with the detection values ​​of other state quantities. Therefore, the cause of abnormalities occurring in the spray application of amorphous refractory materials can be quickly identified, and the abnormality can be quickly corrected.

[0019] Figure 3 conceptually shows the system configuration of an abnormal cause identification system that implements the abnormal cause identification method described above. The abnormal cause identification system 100 of this embodiment includes a detection value acquisition unit 101 that acquires detection values ​​of multiple state quantities related to the spraying of amorphous refractory materials from multiple sensors, and an abnormal cause identification unit 102 that identifies the cause of the abnormal detection value when an abnormal detection value is detected in the detection values ​​acquired by the detection value acquisition unit 101. The abnormal cause identification unit 102 is pre-programmed with correspondence relationships as illustrated in Figures 2A to D, and when the abnormal cause identification unit 102 detects an abnormal detection value in the detection values ​​acquired by the detection value acquisition unit 101, it identifies the cause of the abnormal detection value based on the above correspondence relationships. [Explanation of Symbols]

[0020] X Spray application device A Conveying Gas B. Spray material C Construction water 1. Gas transport introduction route 11 Strainer 12 Pressure Reducing Valve 13 Solenoid valve 14. Pressure sensor 15. Pressure sensor 16. Pressure sensor 17 Flow Sensor 2 Material Tanks 21 Pressure Sensor 3. Material cutting motor 31 Power Sensor 4. Conveying route (material hose) 5. Spray nozzle 6. Water Injection Route 61 Water Injection Pump 62 Pressure Sensor 63 Flow Sensor 100 Anomaly Cause Identification System 101 Detected Value Acquisition Unit 102 Abnormality cause identification section

Claims

1. An abnormality cause identification method that acquires detection values ​​of multiple state quantities related to the spraying of amorphous refractory materials from multiple sensors, and identifies the cause of an abnormal detection value when an abnormal detection value is detected among the detection values ​​acquired from the multiple sensors, In advance, a correspondence relationship is created between the cause of the abnormal detection value and the detection values ​​of other state quantities excluding the state quantity detected as the abnormal detection value. An abnormality cause identification method, which identifies the cause of an abnormal detection value based on the correspondence relationship when an abnormal detection value is detected among the detection values ​​obtained from the aforementioned multiple sensors.

2. The method for identifying the cause of an abnormality according to claim 1, wherein the state quantities include the flow rate and pressure of gas and water used in the spraying of amorphous refractory materials, and the power consumption of electrically driven equipment.

3. A detection value acquisition unit that acquires detection values ​​of multiple state quantities related to the spraying of unshaped refractory materials from multiple sensors, An abnormal cause identification system comprising: an abnormal cause identification unit that identifies the cause of an abnormal detected value when an abnormal detected value is detected in the detected values ​​acquired by the detected value acquisition unit, The abnormality cause identification unit is pre-programmed with the correspondence between the cause of the abnormal detected value and the detected values ​​of other state quantities, excluding the state quantity detected as the abnormal detected value. The abnormality cause identification unit identifies the cause of the abnormal detected value based on the correspondence relationship when it detects an abnormal detected value among the detected values ​​acquired by the detected value acquisition unit.

4. The abnormal cause identification system according to claim 3, wherein the state quantities include the flow rate and pressure of gas and water used in the spray application of amorphous refractory materials, and the power consumption of electrically driven equipment.

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