Method of constructing interior brickwork

Abstract

To provide a method of constructing bricks according to a desired shape using bricks having variation in dimensions upon production.SOLUTION: There is provided a method for constructing lining bricks of a kiln in which, using two kinds of bricks A, B in which dimensional differences in a width direction between a face on an outer circumferential side and a face on an inner circumferential side are different upon being installed in a kiln, the arrangement order of the two kinds of bricks for constructing an inner circumference of the kiln is planned, the bricks A, B are arranged according to the plan, an installation position of the last arranged brick is measured after the arrangement of a predetermined number of the bricks A, B to calculate a deviation with the planed brick position, and, when the deviation is outside the pre-set allowable range, as a brick to be arranged next, in the two kinds of the bricks A, B, the one reducing the deviation is selected regardless of the arrangement order.SELECTED DRAWING: Figure 7

Description

【Technical Field】 【0001】 The present invention relates to a method for constructing refractory bricks for lining a kiln furnace facility. 【Background Art】 【0002】 In a kiln furnace facility, shaped bricks or unshaped refractories are provided as the inner lining refractory. When constructing bricks manually, mortar is applied to the bricks to make the interval within a certain range, or when mortar is not applied, the bricks are stacked by pressing them against each other to eliminate the joint interval, thereby preventing leakage of molten metal from the furnace. Since bricks are heavy, in order to reduce the burden on workers, they may be constructed mechanically using a robot hand or the like. 【0003】 However, bricks have dimensional variations during manufacturing. When forming a structure, even if the bricks are arranged as designed, they often deviate from the design drawing and misalignment occurs. In this specification, the variation of bricks during manufacturing refers to the difference between the dimensions after manufacturing and the designed dimensions. 【0004】 There are several patterns of variation during brick manufacturing. For example, Figures 2 and 3 show the patterns of measured values ​​for a trapezoidal brick 10, as shown in Figure 1, used for lining the inside of a cylindrical kiln. Figure 2 shows the relationship between the measured values ​​of the left and right sides 10b and 10c of the front side (working surface) of brick 10 in Figure 1, and is an example where the relationship between the dimensions of the two sides has a symmetrical variation with respect to the design dimensions. In this case, if multiple bricks are placed, the variation cancels out and does not result in a large deviation. On the other hand, Figure 3 shows the relationship between the measured values ​​of the upper edge 10a on the front side (working surface side circumferential direction) and the upper edge 10d on the back side (iron shell side circumferential direction) of brick 10, and is an example where the variation is biased in one direction with respect to the design dimensions. In this case, if multiple bricks are placed, the deviation from the design drawing will gradually increase. In brick manufacturing, it is difficult to eliminate dimensional variations, and if the deviation from the design drawings becomes large when constructing by machine, the bricks may interfere with each other or not match the diameter of the furnace shell, making construction impossible. In particular, if there is a large variation in the width (circumferential direction) between the inner circumference side (working surface side) 10a and the outer circumference side (iron shell side) 10d when installing in the furnace, it becomes impossible to install the brick 10 according to the curvature of the furnace. Moreover, in the case of machine construction, it is impossible to make corrections such as processing the brick 10 during construction. 【0005】 Patent Document 1 discloses a method for measuring the dimensions and installation position of a refractory structure when mechanically constructing a refractory structure in a coke oven. 【0006】 Furthermore, Patent Document 2 discloses a method for confirming the position of an object when manipulating it with a robot hand equipped with a lighting device and a television camera. 【0007】 Patent Document 3 discloses an automatic article handling device that prevents articles from colliding or falling due to manufacturing errors or operational errors. [Prior art documents] [Patent Documents] 【0008】 [Patent Document 1] Japanese Patent Publication No. 2017-53765 [Patent Document 2] Japanese Patent Application Publication No. 6-278070 [Patent Document 3] Japanese Patent Application Publication No. 7-9378 [Overview of the Initiative] [Problems that the invention aims to solve] 【0009】 However, Patent Document 1 only describes a method for measuring the shape of bricks, and does not describe a method for installing bricks based on the measurement results. Furthermore, Patent Document 1 assumes a case where refractory material is stacked inside a coke oven, which is different from the circumferential construction of lining bricks in a kiln, which is the subject of the present invention. 【0010】 Patent Document 2 describes a method for measuring the position of an object manipulated by a robot hand, and does not describe a method for setting up the object based on the measurement results. 【0011】 Furthermore, Patent Document 3 describes a technology that uses an angle sensor and a remote measuring device to detect the distance to the object to be transported and any deviations in its placement, and then corrects the movement route and placement position of the object to be transported next time. 【0012】 As described above, none of these methods involve detecting and correcting positional deviations caused by variations in dimensions during manufacturing when constructing bricks. Therefore, the object of the present invention is to provide a method for constructing bricks in a desired shape using bricks that have variations in dimensions during manufacturing. [Means for solving the problem] 【0013】 To solve the above problem, the present invention provides a method for constructing the inner lining of a kiln using two types of bricks, each having a different widthwise dimension between its outer and inner surfaces when installed in the kiln; planning the arrangement order of the two types of bricks for constructing the inner lining of the kiln; arranging the bricks according to the plan; and arranging a predetermined number of bricks. Each time, the predetermined number The present invention provides a method for constructing the inner lining bricks of a kiln, characterized by measuring the installation position of the last placed brick, calculating the deviation from the design brick position, and if the deviation falls outside a predetermined tolerance range, selecting the brick with the shape that minimizes the deviation from the two types of bricks to be placed next, regardless of the order of placement. The aforementioned predetermined number may be one. 【0014】 The two types of bricks may be of two types, one large and one small, in width direction relative to the design dimensions of bricks that can be laid along the inner circumference of the kiln according to the design drawings to construct the entire inner circumference. Alternatively, the two types of bricks may be manufactured with the design dimensions of bricks that can be laid along the inner circumference of the kiln according to the design drawings, and in the actual dimensions measured after manufacturing, may be of two types, one large and one small, in width direction relative to the design dimensions. 【0015】 The installation position of the brick may be determined by measuring at least the inner surface and side surface of the brick using a laser distance meter. 【0016】 The aforementioned displacement may be expressed as the difference between the distance from the corner on the inner circumference side of the brick, which is also on the front side in the direction of construction, to the axis of the kiln, and the distance from the corner at the design position of the brick to the axis of the kiln. 【0017】 The allowable range for the aforementioned deviation may be greater than 0 mm and less than or equal to 2 mm. [Effects of the Invention] 【0018】 According to the present invention, by measuring the installation position of existing bricks and selecting and arranging bricks with a shape that corrects displacement, bricks having dimensional variations during manufacturing can be used to construct bricks into a desired shape by mechanical construction. 【Brief Description of the Drawings】 【0019】 [Figure 1] It is a perspective view showing an outline of the shape of the inner lining brick. [Figure 2] It is a graph showing an example of dimensional variation of two sides of the inner lining brick shown in FIG. 1. [Figure 3] It is a graph showing an example of dimensional variation of the other two sides of the inner lining brick shown in FIG. 1. [Figure 4] It is a perspective view showing an outline of the shapes of two types of bricks according to an embodiment of the present invention. [Figure 5] It is a plan view showing a design example of the arrangement order of two types of bricks. [Figure 6] It is a plan view showing an example of the measurement position of the installation position of the brick. [Figure 7] It is a diagram for explaining an example of a method for detecting displacement of the brick. [Figure 8] It is a diagram for explaining the displacement of the brick when it is displaced in the direction in which the inner diameter of the brick to be constructed becomes larger, and (b) is a partially enlarged view of (a). [Figure 9] It is a diagram for explaining the displacement of the brick when it is displaced in the direction in which the inner diameter of the brick to be constructed becomes smaller, and (b) is a partially enlarged view of (a). [Figure 10] It is a plan view for explaining an example of the arrangement of bricks according to an embodiment of the present invention. 【Embodiments for Carrying Out the Invention】 【0020】 Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the present specification and drawings, elements having substantially the same functional configuration are denoted by the same reference numerals, and redundant description is omitted. 【0021】 This embodiment concerns the construction of the inner brick lining for a kiln furnace. The kiln furnace is roughly cylindrical in shape, and has an iron shell with a roughly circular cross-section on its outer circumference, with bricks provided inside as a refractory material. 【0022】 The bricks used have a trapezoidal planar shape, where the width of the outer surface is greater than the width of the inner surface when placed in the furnace, so that a circumferential structure is formed along the inner circumference of the iron shell of the kiln equipment when multiple bricks are arranged side by side. In this embodiment, as shown in Figure 4, two types of bricks with different trapezoidal inclinations are used: brick A, which has a large difference in width (circumferential direction) between the outer surface (iron shell side) and the inner surface (operating side), and brick B, which has a small difference in width between the outer surface and the inner surface. The difference in width between the outer and inner surfaces of these bricks is formed to be large or small, for example, so as to be symmetrical with respect to the design dimensions that form a circle along the inner circumference of the iron shell with a single type of brick. The difference in width between bricks A and B can be designed, for example, by taking into account the tendency of variation during brick manufacturing. 【0023】 Using these two types of bricks, A and B, the required number of bricks A and B is calculated based on the curvature of the kiln. Furthermore, the arrangement order is planned so that bricks A and B are uniformly placed around the entire circumference, minimizing the change in curvature. Figure 5 shows an example of the arrangement order. Although Figure 5 shows an example representing 1 / 4 of the circumference, by using two types of bricks A and B with different dimensional differences between the outer and inner circumferences, it is possible to accommodate cases where the curvature of the kiln is not constant. 【0024】 Then, following the planned placement sequence, bricks are placed in their designated positions, for example, using a robotic hand. The placement of newly installed bricks is specified to be spaced appropriately, for example, about 10 mm apart from the bricks already in place. After that, to prevent molten metal from leaking out of the furnace, the newly installed bricks are pressed against the existing bricks to eliminate the gaps between the brick joints. Once the predetermined number of bricks have been placed, the placement position of the last brick is measured. 【0025】 The placement position of the bricks can be measured using a laser distance meter. For example, as shown in Figure 6, the laser distance meter 21 can be attached to a robot hand 22 that grasps the brick 10 and places it in a predetermined position, or to a cylinder 23 that presses the placed brick 10 against an existing brick 10. Then, two or more points are measured on the inner surface 10e and the side surface 10f of the placed brick 10. By measuring two or more points on the side surface of the brick 10, the position of the side surface and the placement angle of the brick can be calculated. Similarly, by measuring two or more points on the working surface, the position of the working surface and the placement angle of the brick can be calculated. Furthermore, the intersection point of the calculated side surface and working surface can be taken as the corner 10g of the brick 10, making it possible to determine the position of the placed brick. 【0026】 As a concrete example, the method for determining the position of angle 10g shown in Figure 7 will be explained based on Figure 8. Let S1 and S2 be two measurement points on the side surface 10f of the installed brick 10, and HS1 and HS2 be two measurement points on the inner surface 10e. If the XY coordinate values ​​of each point on the installation plane are measured by a laser distance meter, the XY coordinate values ​​of the intersection of the line S1S2 and the line HS1HS2, i.e., angle 10g of the installed brick 10 (C2 in Figure 8), can be calculated. It is also possible to determine the angle θ between the inner surface 10e and the side surface 10f. Although Figure 8 shows an example where the brick is shifted outward (the inner diameter increases), the same method can be used to calculate the XY coordinate values ​​of angle 10g of the installed brick 10 (C2 in Figure 9) even when the brick is shifted inward (the inner diameter decreases), as shown in Figure 9. 【0027】 The laser distance meter 21 is not limited to being mounted on the robot hand 22 or cylinder 23; it may be fixed in any other location as long as it is in a position that allows for measurement of the brick placement 10. Furthermore, the laser distance meter 21 and robot hand 22 can be standard, commonly available models. 【0028】 Next, the deviation of the actual installation position from the design coordinate position of the brick 10 is detected. In this embodiment, as shown in Figure 7, the deviation is detected by the position of the front corner 10g in the construction direction of the inner circumferential surface 10e of the brick 10, which is the operating surface side of the furnace. Specifically, a circle C is assumed to be inscribed in the inner circumferential surface 10e at the design position of the brick and centered at the furnace center O. The position of the inner circumferential corner 10g of the brick 10 is calculated from the coordinate position of the brick 10 measured at the actual installation position, and the distance d between the point where the line passing through the center O of circle C and the corner 10g intersects circle C and the corner 10g is calculated. 【0029】 A specific example will be explained using Figure 8. Figure 8(b) is an enlarged view of the area within the dashed circle in Figure 8(a). At the design position P of the brick, a circle C is assumed to be inscribed in the inner surface and centered at the furnace center O. The position (XY coordinate value) C2 of the inner corner 10g of the actually installed brick 10 is calculated using the method described above, and the distance d2 between the point R2 where the line OC2 passing through the center O and the corner 10g of the brick 10 intersects with circle C and the corner 10g of the brick is calculated. If the displacement is in the direction of increasing the inner diameter, the distance d2 should be a positive value. Alternatively, the distance d2 may be obtained by subtracting the radius of circle C from the distance between the center O and the corner 10g. Figure 8 is an example where the brick 10 is shifted outward (increasing the inner diameter), but as shown in Figure 9, the distance d2 can be calculated in the same way even when the brick 10 is shifted inward (decreasing the inner diameter). Figure 9(b) is an enlarged view of the area within the dashed circle in Figure 9(a). If the displacement is in the direction that reduces the inner diameter, the distance d should be a negative value. In this case as well, the distance d2 may be obtained by subtracting the radius of circle C from the distance between the center O and angle 10g. 【0030】 The distance d2 calculated for the installed brick 10 is compared with the distance d1 at the design position P. If this difference exceeds a predetermined tolerance, it is determined that the inner diameter of the structure during brick construction deviates from the design dimensions. A specific example is explained using Figure 8. Using the method described above, the distance d2 for the installed brick 10 can be determined, while the distance d1 at the design brick position P can also be calculated. The absolute value of the difference between the distance d2 for the installed brick 10 and the design distance d1 (|d2-d1|) is defined as the deviation. If this deviation exceeds a predetermined tolerance, it is determined that the inner diameter of the structure during brick construction deviates from the design dimensions. In the above example, the distance d2 was defined as shown in Figures 8 and 9 to calculate the deviation. This deviation is equivalent to the numerical difference between the distance from the corner 10g of the brick 10 measured at the installation position to the axis O of the kiln, and the distance from the corner at the design brick position P to the axis O of the kiln. 【0031】 As illustrated in Figure 10, after arranging four bricks B in the direction of the arrow, if the displacement |d2-d1| of the fourth brick B exceeds the allowable range and deviates from the design position shown by the dotted line in a direction that increases the inner diameter, then the next brick to be installed should be brick A, regardless of the plan, and the curvature should be corrected in a direction that decreases the inner diameter. 【0032】 Contrary to the example in Figure 10, if it is determined that the inner diameter of the structure during brick construction is smaller than the design dimensions, then brick B is selected for the next brick to be placed, regardless of the original plan, and the curvature is corrected in the direction that increases the inner diameter. If the deviation is within the acceptable range, it is determined that the structure was built with the curvature as originally designed, and the bricks are placed in the original planned arrangement order. 【0033】 As described above, by detecting deviations caused by variations in brick manufacturing during brick placement and selecting and placing bricks with shapes that correct the curvature as needed, it becomes possible to eliminate the need to process the bricks during construction and enable mechanical construction. In this embodiment, deviations are detected every time a predetermined number of bricks are placed, but in order to keep the curvature of the constructed brick structure as constant as possible, deviations may be detected each time a single brick is placed. 【0034】 The allowable range for the displacement |d2-d1| can be set appropriately according to the size and shape (curvature) of the kiln, for example, it may be greater than 0 mm and less than or equal to 2 mm. 【0035】 With the above construction method, it is possible to construct the desired shape without making any modifications such as processing the bricks during construction, thus enabling mechanical construction. 【0036】 In the above embodiment, bricks A and B were two types with different design dimensions during brick manufacturing. However, if a single type of brick is manufactured with the same design dimensions that can form a circumference along the inner circumference of the steel shell, and the manufacturing variation is distributed as shown in Figure 2, then one distribution relative to the design dimensions may be designated as brick A (for example, the one with a larger difference in width between the outer and inner circumferences), and the other distribution as brick B (for example, the one with a smaller difference in width between the outer and inner circumferences). 【0037】 Preferred embodiments of the present invention have been described above, but the present invention is not limited to these examples. It will be obvious to those skilled in the art that various modifications or alterations can be conceived within the scope of the technical idea described in the claims, and these will naturally also fall within the technical scope of the present invention. [Examples] 【0038】 A test was conducted to simulate a molten steel pot-shaped furnace with a radius of 2000 mm and a capacity of 350 tons, and to mechanically construct the inner brick lining using a robotic hand. 【0039】 Two types of bricks were prepared: brick A, which has a large difference in dimensions between its inner and outer circumference, and brick B, which has a small difference in dimensions between its inner and outer circumference. Based on the design dimensions of bricks A and B, a plan was drawn to ensure that the structure could be constructed to match the curvature of the kiln. It was determined that construction following the curvature of the kiln could be achieved by arranging the bricks in the order BBB→AA→BBB→AA.... Variations in brick manufacturing were not considered in the arrangement plan. In this case, although construction is theoretically possible based on the design dimensions of the bricks, the arrangement of brick B is more numerous, which may result in a larger inner diameter when actually constructed. 【0040】 After placing one brick, when placing the next brick, the next brick was placed with an installation gap of approximately 10 mm relative to the design position. Then, the brick was pushed laterally with a lateral pushing cylinder to bring it closer to the previously placed brick, eliminating any gaps between the bricks during construction. 【0041】 [Example of the present invention] Following the plan on the drawing, the bricks were placed in the order BBB→AA→BBB→AA. Each time a brick was placed, its position was measured using a laser distance meter, and the distance d2 shown in Figure 8 was calculated. The distance d1 at the design position P was 0.3 mm. In this example, the upper limit of the allowable deviation |d2-d1| was set to 1.7 mm, and since 1.7 ≥ |d2-d1|, the upper limit of the distance d2 at the placement position was set to 2 mm. That is, when the distance d2 exceeded 2 mm, it was determined that a deviation was occurring in the direction of increasing radius. In this case, brick A was selected for the next brick to be placed, regardless of the placement plan, and the correction was made in the direction of decreasing radius. If the distance d2 was within 2 mm, the bricks were placed as planned. Although it did not occur in this example, if a deviation occurred in the direction of decreasing radius, the distance d2 at the placement position would be a negative value. In this case, if the upper limit of the allowable range of displacement |d2-d1| is set to 1.7 mm, then from 1.7 ≥ |d2-d1|, the upper limit of the distance d2 at the installation location becomes -1.4 mm. If the value of d2 becomes smaller than -1.4 mm, it is determined that a displacement is occurring in the direction of decreasing radius, and the next brick to be installed will be brick B, regardless of the layout plan, and the correction will be made in the direction of increasing radius. 【0042】 As a result of constructing the bricks using the method described above, as shown in Table 1, sufficient spacing between bricks could be ensured, and mechanical construction was possible up to a 90° range inside the furnace without the bricks coming into contact with each other during installation. The installation spacing was designed to be 10 mm, and the actual spacing may increase or decrease due to shifts in the brick placement position caused by the shape of the bricks, etc. If the value is negative, there is no spacing between bricks, they will come into contact with each other, and construction will not be possible. The installation spacing in Table 1 is the result of calculating the distance from the design value for the placement of the later-placed bricks to the measured placement position of the side of the first-placed bricks. Note that in Table 1, distances d2 exceeding 2 mm are underlined. 【0043】 [Table 1] 【0044】 [Comparative Example] When the bricks were placed in the order BBB→AA→BBB→AA according to the planned layout on the drawing, it was observed that the brick placement positions gradually shifted from the design positions, making it impossible to maintain sufficient spacing between bricks. As shown in Table 2, when the 24th brick was placed, the spacing became negative, causing the bricks to come into contact with each other, making further construction impossible. 【0045】 [Table 2] [Industrial applicability] 【0046】 This invention can be applied as a method for mechanically constructing standardized objects that exhibit dimensional variations during manufacturing. [Explanation of symbols] 【0047】 10 bricks 10e Inner circumferential surface 10f side 10g square 21 Laser rangefinder 22 Robot Hand 23 liters A, B bricks C yen O center d, d1, d2 distance

Claims

[Claim 1] A method for constructing the brick lining of a kiln, When installed in the kiln, two types of bricks with different widthwise dimensions between their outer and inner surfaces are used, and the arrangement order of these two types of bricks for constructing the inner circumference of the kiln is planned. Bricks are laid according to the plan, and after each predetermined number of bricks has been laid, the position of the last brick placed is measured, and the deviation from the design brick position is calculated. A method for constructing the inner lining bricks of a kiln, characterized in that, if the aforementioned displacement falls outside a predetermined tolerance range, the next brick to be placed is selected from the two types of bricks, the one with a shape that reduces the aforementioned displacement, regardless of the arrangement order. [Claim 2] The method for constructing the inner lining bricks of a kiln according to Claim 1, wherein the predetermined number is one. [Claim 3] The method for constructing the inner lining bricks of a kiln according to claim 1, characterized in that the two types of bricks are of two types, large and small, in terms of the dimensional difference in the width direction relative to the design dimensions of bricks that can be arranged along the inner circumference of the kiln according to the design drawings to construct the entire inner circumference. [Claim 4] The method for constructing the inner lining bricks of a kiln according to claim 1, characterized in that the two types of bricks are manufactured to design dimensions that allow the entire inner circumference of the kiln to be constructed by arranging them along the inner circumference of the kiln according to the design drawings, and in the actual dimensions measured after manufacturing, there are two types of differences in the width direction from the design dimensions: large and small. [Claim 5] The method for constructing the inner lining bricks of a kiln according to claim 1, characterized in that the installation position of the bricks is determined by measuring at least the inner surface and side surface of the bricks using a laser distance meter. [Claim 6] The method for constructing the inner lining bricks of a kiln according to claim 1, characterized in that the aforementioned deviation is expressed as the difference between the distance from the corner on the inner circumference side of the brick and the front side in the direction of construction to the axis of the kiln, where the installation position was measured, and the distance from the corner at the design position of the brick to the axis of the kiln. [Claim 7] The method for constructing the inner lining bricks of a kiln according to claim 6, characterized in that the allowable range of the deviation is greater than 0 mm and less than or equal to 2 mm.