Monitoring system for electrode coupling devices

Abstract

An electrode coupling monitoring system for use with a device configured to apply torque to a first electrode to screw-couple the first electrode to a second electrode. The device is configured to output torque values ​​regarding the applied torque. The system includes a controller configured to receive torque values ​​and analyze the received torque values ​​to identify a screw engagement step in which the first electrode is screw-coupled to the second electrode or was screw-coupled. The controller is also configured to identify an end face engagement step in which the end face of the first electrode contacts or was in contact with the end face of the second electrode.

Description

Technology Field

[0001] This application claims priority to U.S. provisional application serial number 63 / 613,198, titled Monitoring System for an Electrode Coupling Device, filed on December 21, 2023, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to a monitoring system for use with a device for coupling electrodes, and more specifically, to such a monitoring system for detecting when electrodes are properly coupled / not coupled. Background Technology

[0003] Electrode coupling devices can be used to join two electrodes together, for example, by screwing the electrodes together. When the electrodes are joined to form an electrode column, the electrode column can be mounted in an electric arc furnace. When joining electrodes together, the connection must be safe and complete. In particular, incomplete or defective connections can result in poor performance of the electrodes and may also lead to breakage or failure of the electrodes during use. Such poor performance, breakage, and / or failure can result in reduced performance and / or complete shutdown of the furnace, which can cause significant loss of revenue for the furnace operator.

[0004] In one embodiment, the present disclosure relates to an electrode coupling monitoring system for use with a device configured to apply torque to a first electrode to screw-couple the first electrode to a second electrode. The device is configured to output torque values ​​regarding the applied torque. The system includes a controller configured to receive torque values ​​and analyze the received torque values ​​to identify a screw engagement step in which the first electrode is screw-coupled to the second electrode or was screw-coupled. The controller is also configured to identify an end face engagement step in which the end face of the first electrode contacts or was in contact with the end face of the second electrode.

[0005] Some embodiments of the present disclosure relate to systems, methods, and / or computer-readable storage media for an electrode coupling monitoring system to be used with a device configured to apply torque to a first electrode to screw-couple a first electrode to a second electrode, wherein the device is configured to output torque values ​​regarding the applied torque. These and other embodiments may each optionally include one or more of the various features described below.

[0006] According to some embodiments, a non-transient computer-readable storage medium stores computer-executable instructions to perform or cause to perform any of the methods described herein. According to some embodiments, a device comprises one or more processors, a non-transient memory, and one or more programs; one or more programs are configured to be stored in the non-transient memory and executed by one or more processors, and one or more programs include instructions to perform or cause to perform any of the methods described herein. Brief explanation of the drawing

[0007] Figure 1 is a perspective view of a pair of spaced electrodes. FIG. 2 is a schematic diagram of an electrode coupling device shown with the electrodes of FIG. 1 in an uncoupled position. FIG. 3 illustrates the system of FIG. 2, in which the electrodes are initially joined together in the axial direction. FIG. 4 illustrates the system of FIG. 3 in which the electrodes are rotated relative to each other to further combine the electrodes together. Figure 5 illustrates the system of Figure 4 in which the electrodes are completely coupled together. FIG. 6 shows the electrodes of FIG. 1–5 joined together to form an electrode pillar. FIG. 7 is a graph illustrating the expression of the applied pressure / torque of the device of FIG. 2 in an exemplary suitable combination of electrodes. FIG. 8 is a graph illustrating the expression of the applied pressure / torque of the device of FIG. 2 in another exemplary suitable combination of electrodes. FIG. 9 is a graph illustrating the expression of the applied pressure / torque of the device of FIG. 2 in a defective combination of electrodes. FIG. 10 is a graph illustrating the expression of the applied pressure / torque of the device of FIG. 2 in a different defective combination of electrodes. FIG. 11 is a graph illustrating the expression of the applied pressure / torque of the device of FIG. 2 in another defective combination of electrodes. FIG. 12 is a flowchart illustrating an overview of a system and method for monitoring electrode couplings. FIG. 13 is a flowchart illustrating a more detailed implementation of an example of a system and method for monitoring electrode coupling. FIG. 14 is a block diagram illustrating device components of an exemplary device according to certain implementations. It should be noted that the various features illustrated in the drawings may not be drawn to scale. Therefore, the dimensions of the various features may be enlarged or reduced at will for clarity. Additionally, some of the drawings may not depict all components of a given system, method, or device. Finally, the same reference numbers may be used throughout the specification and drawings to denote the same features. Specific details for implementing the invention

[0008] Referring to FIGS. 1–6, the system and method disclosed herein may include and / or be used with a coupling device (10) configured to combine a first electrode (12) and a second electrode (14). The first and second electrodes (12 and 14) may be generally cylindrical, each having a respective opposing axial end face (16, 18). The first electrode (12) has a screw pin (20) on / on the end face (16). The pin (20) may be formed integrally with the electrode (12) or, alternatively, may be a separate component screwed into the first electrode (12). The second electrode (14) has a screw socket (22) corresponding to / on the axial end face (18). In the illustrated embodiment, both the pin (20) and the socket (22) are generally truncated and have threads formed on their respective outer / inner surfaces. The pin (20) is configured to be screwed into the socket (22) to join the first and second electrodes (12 and 14) together. Alternatively, the positions of the pin (20) and the socket (22) can be reversed so that the pin (20) is on the second electrode (14) and the socket (22) is on the first electrode (12).

[0009] The coupling device (10) may include a pair of gripping parts (24, 26), each configured to grip one of the electrodes (12, 14). At least one of the gripping parts (24, 26) (rotating gripping part (24) in the illustrated embodiment) is configured to rotate about the other electrode (12, 14) / gripping part (24, 26) around the central axis of the electrodes (12, 14) / gripping parts (24, 26). At least one of the gripping parts (24, 26) is also configured to move axially to enable the electrodes (12, 14) to be coupled to each other. The rotating gripping part (24) may be torqueed by a driving force, such as pneumatic fluid, electric current, or other power / torque sources, so as to be able to apply torque to the gripped electrode (12).

[0010] To use the coupling device (10) and to combine the electrodes (12, 14) (also referred to as the electrode addition process), the first electrode (12) is gripped by the gripping member (24) and / or lifted by the gripping member (24), or lifted by a separate hoist, crane, lift, or other lifting component. Then, as shown in FIG. 1, the first electrode (12) is positioned so that the pin (20) of the first electrode (12) is axially aligned with the socket (22) of the second electrode (14). Then, as shown in FIG. 3, the first electrode (12) is lowered until the pin (20) is loosely received in the socket (22). Then, the gripping member (24) is rotated about the central axis of the electrodes (12, 14), which in turn causes the pin (20) to be screwed into the socket (22). As illustrated in FIG. 4, when the pin (20) is fully screwed into the socket (22), the end faces (16, 18) of the electrodes (12, 14) are adjacent to each other in planar-to-planar contact, the pin (20) cannot be further screwed into the socket (22), and the electrodes (12, 14) are considered to be fully and properly connected.

[0011] The operation of the electrode coupling device (10) is generally implemented manually. In particular, an operator may trigger a switch to cause the rotary gripper (24) to rotate, which allows or enables the driving force to apply torque to the electrode (12) to screw the pin (20) into the socket (22). (In one case, a human) The operator observes the screw coupling process, and when the operator observes and / or detects that the pin (20) is fully screwed into the socket (22) (e.g., due to visual confirmation and / or audio signals such as hearing the sound of the end faces (16, 18) coming into contact with each other or hearing the sound that the driving force needs to work harder), the operator may turn off the power / driving force and cause the rotary gripper (24) to stop rotating. When the screw coupling operations are completed, the end faces (16, 18) of the electrodes (12, 14) come into contact with each other. Next, the operator is generally required to "bump" the electrode (12) by triggering the coupling device (10) with a series of short torques (typically 2-3 times) applied to the rotary gripping part (24) to ensure that the first and second electrodes (12, 14) are fully and properly coupled.

[0012] When the first and second electrodes (12 and 14) are combined with each other, they together form an electrode column (17) as shown in FIG. 6 (or combined with an existing electrode column including other electrodes (not shown)). Subsequently, the electrode column (17) is positioned in an electric arc furnace or forms part of an electric arc furnace. Once mounted in the furnace, electricity passes through the electrode column (17) and any other electrode columns of the electric arc furnace to generate high temperatures to melt metals or other materials for further processing, for example.

[0013] Each electrode (12, 14) may be made substantially or primarily of carbon and / or carbonaceous material (e.g., at least 80% in the case of, or at least 90% in the other case, or comprising carbon and / or carbonaceous material on a weight and / or volume basis). In the case of, each electrode (12, 14) is made substantially or primarily (e.g., at least 80% in the case of, or at least 90% on a weight / or volume basis in the other case) of graphite, the graphite being a graphitized mixture of coke such as needle coke, calcined petroleum coke, or calcined anthracite, and a binder such as pitch, coal tar pitch, or petroleum pitch, which is formed, fired, impregnated, graphitized, and machined. Each electrode (12, 14) may be relatively electrically conductive, maintaining shape and dimensional characteristics, and in the case of, 20 A / cm² 2 Exceeding, or in other cases 30 or 35 A / cm 2 Current densities exceeding can be accommodated. In the case where, the electrical resistivity of the electrodes (12, 14) is greater than about 2 micro-Ohm*meter, and in the other case, less than about 20 micro-Ohm*meter.

[0014] Each electrode (12, 14) may be heated to a temperature of at least about 2,800°C in one case, or at least about 3,000°C in another case, or at least about 3,200°C in yet another case, while maintaining its shape and dimensional characteristics and electrical conductivity. U.S. Patent No. 10,237,928, incorporated herein by reference in its entirety, discloses such electrodes and methods for making such electrodes, and discloses materials and methods that may be used to make the electrodes (12, 14) described herein.

[0015] The electrode coupling device (10) may be configured to detect / measure the torque applied to the electrode (12) by the coupling device (10) / rotating gripper (24) through one or more sensors, schematically illustrated in FIG. 2 as sensors (28, 28'). In the case where the electrode coupling device (10) is pneumatically driven, the electrode coupling device (10) may have a hydraulic supply line (31). In this case, the sensor (28) may be located on / at the supply line (31) and the sensor (28) may detect the pressure of the operating / pneumatic fluid which may be directly proportional to (or have some other known / predictable relationship with) the torque applied by the gripper (24) and / or to the gripped electrode (12). In another case, if the coupling device (10) is electrically driven, the supply line (31) may be a cord / electrical conductor, and the sensor (28) may detect a current and / or voltage flowing / applied to the coupling device (10) and / or the gripping part (24) that may be directly proportional to the torque applied to the electrode (12) (or have some other known relationship). In yet another case, the sensor (28') may be located on / at the gripping part (24) itself to detect the applied torque.

[0016] Accordingly, the sensor (28, 28') may provide an output related to and / or indicating the torque applied by the coupling device (10) / grappling part (24). When the coupling device (10) / grappling part (24) is operated but the electrodes (12, 14) are not screwed together (e.g., during the steps illustrated in FIG. 2 and FIG. 3), the output of the sensor (28, 28') is expected to be relatively low, and may be 0 or effectively 0 (negligible values). In contrast, when the coupling device (10) / grappling part (24) screws together the electrodes (12, 14) (e.g., during the step illustrated in FIG. 4), the measured torque is expected to be greater than 0, but still relatively low. Finally, when the screw connection is completed and the end faces (16, 18) are adjacent to each other (e.g., during the step shown in FIG. 5), but the coupling device (10) is still in operation, the electrodes (12, 14) resist further rotation and the applied torque is significantly increased accordingly, so the measured / output torque is expected to be relatively high.

[0017] Sensors (28, 28') can be operably coupled to a controller (generally designated as 30) so that the output of the sensor (28, 28') (e.g., pressure, current, voltage, or any other measurement of an applied torque) is provided to the controller (30). The output of the sensor (28) may be considered a “torque value” even if the output is not necessarily provided in torque units (e.g., lb.-ft). The controller (30) may take any of many different forms, but in some cases, it is a controller, processor, computer, CPU, or similar (collectively referred to as “controller”) having memory and non-transient, computer-readable program instructions to enable the controller (30) to perform the steps and processes presented below.

[0018] The controller (30) is configured to receive outputs (e.g., data or torque values) from the sensor(s) (28, 28') and to analyze the received data / torque values ​​to determine when the electrodes (12, 14) are properly and / or improperly coupled. In particular, the controller (30) is configured to analyze the received torque values ​​to identify a screw engagement step (32) in which the first electrode (12) is screw-coupled to the second electrode (14) (as shown in FIG. 4). The controller (30) is also configured to identify an end face engagement step (34) in which the end face (16) of the first electrode (12) contacts the end face (18) of the second electrode (14) and / or the first and second electrodes (12 and 14) are fully screw-coupled (as shown in FIG. 5).

[0019] FIGS. 7 and 8 provide exemplary graphs of the output of the sensor(s) (28) during the proper coupling of the electrodes (12, 14). In these figures, the vertical axis represents the measured pressure (in psi) applied by the coupling device (10) (e.g., when torque is applied by the rotary gripper (24) by pneumatic fluid), which can be considered to be directly related to the applied torque values ​​(in lb.-ft) as mentioned above. The horizontal axis represents time (divided into seconds in the illustrated embodiment).

[0020] At the start of the electrode coupling process, in step (27) of FIGS. 7 and 8, the pressure / torque values ​​are relatively low and constant, being zero or close to zero, and the pin (20) and socket (22) do not engage or contact each other (which may be referred to as the pre-screw engagement step (27)). Subsequently, as the pin (20) engages with the socket (22) and is screwed into the socket (22), the pressure / torque values ​​increase significantly but remain relatively constant (at a pressure of about 500 psi in FIGS. 7 and 8). Accordingly, when the pressure / torque value exceeds a minimum pressure / torque value (33) (about 300 psi in the embodiment of FIG. 7 and 8), which is a predetermined value / threshold, and is subsequently maintained at a relatively constant or exceeds the minimum pressure / torque value (33) for a predetermined time period, the system is determined to exit the pre-screw engagement stage (27) and enter the screw engagement stage (32) (at about 12:08:43 AM in the embodiment of FIG. 7 and at about 10:40:42 PM in the embodiment of FIG. 8).

[0021] Accordingly, the system / controller (30) is configured to identify the system as entering or being in the screw engagement stage (32) when pressure / torque values ​​are maintained at values ​​exceeding the minimum pressure / torque value (33) for a predetermined time period (or within a predetermined time period, for example, at least about 10 seconds in the case of, or at least about 20 seconds in the case of, and at least about 30 seconds in other cases), but are still maintained at relatively low and relatively normal torque values ​​(in the case of, below the end face critical pressure / torque (40) which will be described in more detail below). The measured pressure / torque values ​​are expected to remain relatively constant during the screw engagement stage (32) during proper screw engagement / connection, and the system is basically in a normal state.

[0022] The system / controller (30) may be configured to identify the end face engagement step (34) by determining that pressure / torque values ​​reach relatively high values ​​after the start of the screw engagement step (32). In particular, the coupling device (10) may have a nominal maximum pressure / torque (38) (maximum torque), which is an upper limit of the pressure / torque that can be applied by the coupling device (10). When the measured pressure / torque values ​​sufficiently approach the nominal maximum pressure / torque (38), the system / controller (30) may determine that the system / process has exited the screw engagement step and entered the end face engagement step (34). In the case where the measured pressure / torque values ​​are within 10% of the nominal maximum pressure / torque (38), or within 20% in another case, or within 30% in another case, or within 40% in yet another case, the system can be determined to be in the end face engagement stage (34).

[0023] In the embodiments of FIGS. 7 and 8, the nominal maximum pressure / torque (38) may be set to and / or assumed to be about 2150 psi, and the threshold psi for entering the end face engagement step (end face threshold pressure / torque (40)) is set to 1750 psi (in this case, about 18.6% of the nominal maximum pressure / torque (38)). Thus, in the embodiment of FIG. 7, the system is determined to have entered the end face engagement step (34) (and exited the screw engagement step (32)) at a time of about 12:09:28 AM. In the embodiment of FIG. 8, the system is determined to have entered the end face engagement step (34) at a time of about 10:41:26 PM. The system / controller (30) may subsequently (or at a later time) calculate the screw engagement time, which is the amount of time the system was in the screw engagement phase (32) (about 45 seconds in the embodiment of FIG. 7, about 44 seconds in the embodiment of FIG. 8). The system / controller (30) may also be configured to determine the average pressure / torque applied during the screw engagement phase (32) (screw engagement phase average pressure / torque (35); about 550 psi in the embodiment of FIG. 7 and about 520 psi in the embodiment of FIG. 8).

[0024] During the end face engagement step (34), as the operator applies power to the electrode coupling device (10) for a short period of time, the measured pressure / torque, as illustrated in FIGS. 7 and 8, may reach several peaks and result in several short peaks of pressure / torque at several "bumps" that ensure the screw surfaces (20, 22) are fully engaged. When the operator is satisfied that there is sufficient engagement, the operator reduces and / or terminates the power to the electrode coupling device (10), and the measured pressure / torque drops below the minimum pressure / torque value (33) (about 300 psi in the illustrated embodiment) and enters the shutdown step (47).

[0025] When the measured pressure / torque value is maintained below the minimum pressure / torque value (33) for a predetermined time period (e.g., 10 seconds in the case of), the end face engagement step (34) may be determined to have ended (e.g., “retrospective” or “retrospective-calculated”) at the time when the pressure first dropped below the minimum pressure / torque value (33) and was maintained below the minimum pressure / torque value (33) for the said predetermined time period. Since the measured torque values ​​may drop relatively low (below the minimum pressure / torque value (33)) immediately after the bump, as illustrated in the end face engagement steps (34) of FIGS. 7 and 8, a minimum time requirement (such as 10 seconds in one embodiment) may be useful to ensure that the end face engagement step (34) is not determined to have ended prematurely. Accordingly, in the embodiment of FIG. 7, the system is determined to exit the end face stage (34) at approximately 12:09:46 AM and enter the shutdown stage (47). In the embodiment of FIG. 8, the system is determined to exit the end face stage (34) at approximately 10:41:48 PM and enter the shutdown stage (47).

[0026] The system / controller (30) may subsequently (or at a later time) calculate the end face engagement time, which is the amount of time the system was in the end face engagement phase (34) (about 18 seconds in the embodiment of FIG. 7 and about 22 seconds in the embodiment of FIG. 8). The system / controller (30) may subsequently (or at a later time) calculate the total assembly time, which is the sum of the end face engagement time and the screw engagement phase time (63 seconds in the embodiment of FIG. 7 and 66 seconds in the embodiment of FIG. 8). The system / controller (30) may also track / determine the maximum end face phase pressure / torque (42), which is the maximum pressure / torque applied / sensed during the end face engagement phase (34) (about 1950 psi in the embodiments of FIG. 7 and 8).

[0027] The system / controller (30) may be configured to determine and store predetermined values / thresholds and calculated / tracked values ​​of the electrode coupling process, including all values / thresholds described above and pressure / torque values, upper and lower limit ranges, screw engagement time, end face engagement time, total assembly time, average pressure / torque of the screw engagement stage, maximum end face stage pressure / torque (42), etc., described below, and their averages, medians, and standard deviations, in the history database (44). Such values ​​may be collected and stored during a calibration period in which the electrode coupling process is closely monitored to ensure proper electrode coupling, and data from such proper couplings is stored in the history database (44).

[0028] The distribution of values ​​and / or the mean and / or median of the related values ​​may also be calculated and / or stored in the history database (44). The history database (44) may also include other information related to the electrodes (12, 14) and / or the bonding process, including, in some cases, the operator / owner of the electrodes (12, 14) and the name or other identification information of the associated furnace, the name or other identification information of the associated furnace, the number or other identification information of the heat cycle using the electrodes (12, 14), the start time of the assembly / bonding process, the end time of the assembly / bonding process, etc.

[0029] Values ​​in the history database (44) may be updated over time, and values ​​for appropriate electrode combinations may be added to the history database (44) over time, wherein "appropriate electrode combinations" may be determined by the system / controller and / or user, including using the parameters summarized below in some cases. On the other hand, data from improper / defective combinations may be excluded from the history database (44) in certain cases summarized below.

[0030] New values ​​added to the history database (44) may be weighted more heavily, less heavily, or equally over older values ​​according to operator preferences. In some cases, the history database (44) may include only data from relatively recent combinations; for example, those that occurred within the last 90 days in one case, or those that occurred within the last 45 days in another, or those that occurred within the last 15 days in yet another. The history database (44) may also exclude data from very recent combinations, for example, combinations performed on the same day as the electrode combination under consideration, if desired. The history database (44) may be maintained on a device-by-device basis; that is, each electrode combination device (10) may have its own history database (44), or the data may be aggregated if desired.

[0031] Improper or defective coupling of the electrodes (12, 14) may have various causes such as foreign matter / obstruction in the socket (22) and / or on the pin (20), misaligned screw coupling of the pin (20) / socket (22), defective or misaligned threads, or operator error. The system / controller (30) may be configured to monitor the electrode coupling process to determine whether there is improper coupling, and if so, transmit a notification (e.g., to the operator of the coupling device (10), or to a remote entity / controller, or elsewhere), and / or automatically stop the coupling process (e.g., block any further operation of the coupling device (10) / grip (24) in the case of). Upon notification of an improper connection, the operator may, at the operator's choice, take various measures such as retrying the connection, stopping the connection and inspecting the electrodes (12, 14) / threaded surfaces (20, 22), cleaning the electrodes (12, 14) / threaded surfaces (20, 22), performing other corrective measures, or discarding one or both of the electrodes (12, 14). By detecting defective or potentially defective electrode connections, the system and method disclosed herein may give the operator an opportunity to take corrective measures before positioning the electrodes (12, 14) / electrode posts (17) in the furnace.

[0032] Screw engagement step threshold

[0033] In this case, the pressure / torque measured during the screw engagement step (32) is monitored, and if the measured pressure / torque differs sufficiently from a predetermined limit, the system / controller (30) may determine that the electrodes (12, 14) may be improperly engaged. More specifically, if the measured pressure / torque value deviates sufficiently from the predetermined limits during the screw engagement step (32) compared to the historical pressure / torque values ​​during the screw engagement step (32), the system / controller (30) may send a notification or automatically stop the engagement process. In the case where the average and / or median of the pressure / torque measured during the screw engagement step (32) differs from the average and / or median of the historical pressure / torque of the screw engagement step by + / - 10% or + / - 20%, or by 1 standard deviation of the historical pressure / torque data, or by 2 standard deviations in other cases, the system / controller (30) may flag a defective / improper engagement.

[0034] The threshold value tracked at this stage (e.g., + / - 10%, + / - 20%, 1 standard deviation, or 2 standard deviations, etc.) may be referred to as the screw engagement stage threshold value. Referring to FIG. 7, for example, if the screw engagement stage average pressure / torque during the screw engagement stage (32) is 500 psi and the screw engagement stage threshold value is set to 10%, if the average and / or median pressure / torque values ​​measured during the screw engagement stage (32) exceed 550 psi and / or fall below 450 psi, the system / controller (30) may flag an improper engagement.

[0035] Additionally, the amount by which the screw engagement step threshold is exceeded may be considered in determining whether there is a defective join. For example, in certain cases, if desired, as another check, the joining process is considered adequate as long as the predetermined check value is not exceeded a predetermined number of times (e.g., 1, 2, 3 or more) during the screw engagement step (32). Thus, instead of considering the average and / or median (as in the example described above), the check value considers single or instantaneous torque values. The numeric value assigned to the check value may be related to the screw engagement step threshold in the case of , and may be 4 times the screw engagement step threshold or 200 psi in the case of . However, the check value may be, for example, twice the screw engagement step threshold, or three times the screw engagement step threshold, or five times the screw engagement step threshold, or any multiple of two to ten times the screw engagement step threshold (for example, the check value may be a factor or multiple of the screw engagement step threshold, including fractional / decimal factors or multiples). If the measured torque values ​​exceed the check value in this way, this may be evidence of an example of a misaligned screw connection or dirty threads, where the applied pressure overcomes irregular friction.

[0036] In addition to being flagged as a defective connection, any electrode connections that are flagged as exceeding the screw engagement step threshold and / or check value may be excluded from the history database (44) and not included as part of it because the electrode connection may be considered defective.

[0037] Pressure / torque difference percentage

[0038] The system / controller (30) can also track, calculate, and / or monitor the pressure / torque difference percentage, which is the percentage of the difference between the maximum end face stage pressure / torque (42) and the screw engagement stage average pressure / torque (35) compared to the maximum end face stage pressure / torque (42), as shown in the following mathematical formula:

[0039]

[0040] Accordingly, in the embodiment of FIG. 7, when the maximum end face step pressure / torque (at position 42) is 1950 and the screw engagement step average pressure / torque is 500 psi, the percentage of pressure / torque difference is (1950 psi - 500 psi) / 1950 psi x 100, which is a value of 74.35%. The value of 74.35% represents the percentage of the total pressure applied during the end face engagement step (34); in other words, among the total torque applied / achieved during assembly (joining process), 74.35% of that torque in this case can be considered to have been applied during the end face engagement step (34).

[0041] If the pressure / torque difference percentage exceeds predetermined limits compared to the historical pressure / torque difference percentage, the system / controller (30) may send a notification or automatically stop the coupling process. If the pressure / torque difference percentage differs from the mean and / or median of the historical pressure / torque difference percentage by + / - 10% in one case, or by + / - 20% in another case, or by one standard deviation of the historical data of the pressure / torque difference percentage data in one case, or by two standard deviations in another case, or is outside the control limits based on the data or previously acceptable (historical) electrode couplings, the system / controller (30) may flag a defective / improper coupling. In other cases, if the percentage of pressure / torque difference for a given assembly / joint is lower than a predetermined value (e.g., the predetermined value may be 65% in one case, 55% in another, or 45% in yet another), the system / controller (30) may flag a defective / improper joint.

[0042] FIG. 9 illustrates an example of a connection where the pressure / torque difference percentage is used to flag a defective / improper connection. In the circular area of ​​FIG. 9, it can be seen that the pressure rises relatively slowly as the system exits the screw engagement stage (32) (but is still inside), and then the system enters the end face engagement stage (34). The relatively slow rise in pressure may indicate an obstruction or other problem on the screw surfaces (20, 22). Accordingly, the relatively slow rise in pressure raises the average pressure / torque (35) of the screw engagement stage, which eventually lowers the pressure / torque difference percentage sufficiently so that the pressure / torque difference percentage threshold can be exceeded, and the connection may be flagged as a defective connection.

[0043] Additionally, any electrode combinations that are flagged as defective, in addition to being flagged as exceeding acceptable ranges for a predetermined percentage of pressure / torque difference (e.g., falling outside 2 standard deviations of the history values), and / or falling below a predetermined value (e.g., falling below 55% of the value), may be excluded from the history database (44) and not included as part of it because the electrode combination may be considered defective / inappropriate.

[0044] Screw engagement time

[0045] The system / controller (30) can also track, calculate, and monitor the screw engagement time, which is the time it takes for the system to complete the screw engagement step (32). In particular, if the measured screw engagement time for a specific engagement differs from the average and / or median of the historical screw engagement time by + / - 10% in one case, or by + / - 20% in another case, or by 1 standard deviation of the historical data of the screw engagement time in another case, or by 2 standard deviations in another case, the system / controller (30) can flag the defective / improper engagement.

[0046] In one embodiment, instead of monitoring the value of the screw engagement time, the system / controller (30) may monitor the percentage of the screw engagement time relative to the total assembly time. Thus, if the screw engagement times as a percentage of the total assembly time differ from the mean and / or median of the history values ​​by + / - 10% in one case, + / - 15% in another case, + / - 20% in yet another case, or by 1 standard deviation of the history data in one case, or 2 standard deviations in another case, the connection may be flagged as a defective / improper connection.

[0047] In this case, since a sufficiently short screw engagement time may indicate a screw obstruction that causes the detected pressure / torque to drop after rising, the system / controller may flag / take action accordingly only on screw engagement times that are below thresholds for historical screw engagement times (e.g., the system may flag only sufficiently short screw engagement times and may not necessarily flag times that are too long). Therefore, in this case, screw engagement times that are less than a predetermined percentage of the total assembly time for the corresponding coupling / assembly time (less than 60% in this case, or less than 50% in other cases) may be flagged. Additionally, any electrode couplings flagged as exceeding an acceptable range for a predetermined screw engagement time(s), in addition to being flagged as defective couplings, may be excluded from the historical database and not included as part of it because the electrode coupling may be considered defective / inappropriate.

[0048] End face interlocking time

[0049] The system / controller (30) can also track, calculate, and monitor the end face engagement time, which is the time it takes for the system to complete the end face engagement step (34). In particular, if the measured end face engagement time for a specific engagement differs from the average and / or median of the historical end face engagement time by + / - 10% in one case, + / - 15% in another case, + / - 20% in yet another case, or by 1 standard deviation of the historical data of the end face engagement time in one case, or by 2 standard deviations in another case, the system / controller (30) can flag a defective / improper engagement.

[0050] In one embodiment, instead of monitoring the value of the end face engagement time itself, the system / controller may monitor the percentage of the end face engagement time relative to the total assembly time. Thus, end face engagement times that are not within + / - 15% of the mean and / or median in one case, for example, within + / - 25% of the mean and / or median in another case, or within 1 standard deviation or 2 standard deviations of the historical data of the historical percentage of the end face engagement time relative to the total assembly time, may be flagged as defective / improper engagement.

[0051] The system / controller may flag / take action accordingly on end-face engagement times that are outside the thresholds for historical end-face engagement times, because a sufficiently short end-face engagement time may indicate that the operator has not sufficiently "bumped" the electrodes (12, 14), which may lead to a defective / improper connection (e.g., the system may flag sufficiently short end-face engagement times). FIG. 10 illustrates a defective electrode connection due to a sufficiently short end-face engagement time. In the embodiment of FIG. 10, the time in the end-face engagement step (34) is about 12 seconds, and the total assembly time is about 54 seconds, so the end-face engagement is about 22% of the total assembly time and thus may be flagged as too short.

[0052] The system / controller may also flag / take action accordingly on end face engagement times (34) that exceed thresholds for historical end face engagement times, as sufficiently long end face engagement times may indicate a misaligned screw connection, misalignment, or that the operator did not follow the proper engagement procedure, which may lead to a defective connection (e.g., the system may flag sufficiently long end face engagement times). Additionally, sufficiently long end face engagement times may indicate excessive bumping that may cause excessive stress on the coupling device (10) and / or electrodes (12, 14). FIG. 11 illustrates a defective electrode connection caused by sufficiently long end face engagement times. In the embodiment of FIG. 11, the end face engagement time (34) is about 47 seconds and the total assembly time is about 74 seconds, so the end face engagement is about 64% of the total assembly time and thus can be flagged as being too long relatively speaking.

[0053] Additionally, any electrode couplings that are flagged as defective / improper couplings, in addition to exceeding acceptable range(s) for predetermined end face engagement times, may be excluded from the history database and not included as part of it because the electrode coupling may be considered defective.

[0054] An overview of the process / method (49) is provided in FIG. 12, where the process begins, for example, with the compilation of pressure / torque data from a suitable assembly in step (48) for inclusion in a history database (44). The compiled data is then transmitted in step (50) (if applicable, via email) and received in the database (step (52)), which may, if applicable, constitute or overlap with the history database (44). Next, in step (54), the received data and history data for a specific assembly / assembly are evaluated, for example, by performing the various calculations and evaluations summarized above. The results of step (54) may result in the detection of an improper (or proper) assembly, which results in a warning being sent to an operator / engineer and / or customer in step (56). The results of step (54) may also be fed back to a controller (30) or similar device capable of generating reports detailing the furnace / electrode coupling and operational performance in step (58), including graphs such as those shown in FIGS. 7-11 and the results of the various parameters and calculations described above.

[0055] Referring to FIG. 13, an exemplary environment (61) of a system that may include a database of baseline assembly data / database (60) is illustrated, which may constitute or overlap with a history database (44). Data for a specific assembly or electrode combination is obtained in step (64). The obtained data is then compared with the history database (44) in the manner summarized above. In the embodiment of FIG. 13, the system transmits warnings when the pressure / torque difference percentage in block (66) is exceeded, and / or when the screw engagement time in block (68) is too short, and / or when the end face engagement time in block (70) is too short, and / or when the end face engagement time in block (72) is too long. Each of these warnings (and / or warnings triggered by exceeding / falling below other parameters summarized above) may be documented in a report in step (74) and / or may result in a warning being transmitted to an operator / engineer and / or customer in step (76).

[0056] The system and method disclosed herein can help furnace operators quickly detect and resolve improper / defective electrode assemblies, which can reduce furnace downtime and provide more efficient operations. Furnace operations can have a higher level of reliability in electrode assemblies that are not determined to be improper, and the system and method can reduce joint failures of electrode pillars (17).

[0057] FIG. 14 is a block diagram of an exemplary device (78), such as a computer system or controller, for executing the software components described herein for the transmission / reception and processing of tasks. The device (78) illustrates an exemplary device or computer configuration for the devices, computers, controllers, etc. described herein (e.g., controller (30) or similar). While specific features are illustrated, those skilled in the art will understand from the present disclosure that various other features are not illustrated for brevity and are not illustrated to avoid obscuring more appropriate modes of the implementations disclosed herein. For that purpose, as a non-limiting example, in some implementations, the device (78) comprises one or more processing units (80) (e.g., microprocessors, ASICs, FPGAs, GPUs, CPUs, processing cores, and / or similar ones), one or more input / output (I / O) devices and sensors (84), one or more communication interfaces (86) (e.g., USB, FIREWIRE, THUNDERBOLT, IEEE 802.3x, IEEE 802.11x, IEEE 802.16x, GSM, CDMA, TDMA, GPS, IR, BLUETOOTH, ZIGBEE, SPI, I2C, and / or similar types of interfaces), one or more programming (e.g., I / O) interfaces (88), one or more displays (90), memory (92), and one or more communication buses (82) for interconnecting these and various other components.

[0058] In some implementations, one or more communication buses (82) include circuitry that interconnects and controls communications between system components. In some implementations, one or more I / O devices and sensors (84) include at least one of a pressure sensor, a voltage sensor, a current sensor and / or similar. In some implementations, one or more displays (90) are configured to provide input data, output data, system status data, or a view of the physical or graphical environment to the user.

[0059] Memory (92) includes high-speed random access memory such as DRAM, SRAM, DDR RAM, or other random access solid-state memory devices. In some implementations, memory (92) includes non-volatile memory such as one or more magnetic disk storage devices, optical disk storage devices, flash memory devices, or other non-volatile solid-state storage devices. Memory (92) optionally includes one or more storage devices located remotely from one or more processing units (80). Memory (92) includes a non-transient computer-readable storage medium.

[0060] In some implementations, memory (92) or a non-transient computer-readable storage medium of memory (92) stores an optional operating system (94) and one or more instruction set(s) (96). The operating system (94) includes procedures for handling various basic system services and performing hardware-dependent tasks. In some implementations, the instruction set(s) (96) includes executable software defined by binary information stored in the form of electrical charges. In some implementations, the instruction set(s) (96) is software executable by one or more processing units (80) to perform one or more of the techniques described herein.

[0061] The instruction set(s) (96) includes an electrode and sensor monitoring / analysis instruction set (98). The instruction set(s) (96) may be implemented as a single software executable file or multiple software executable files.

[0062] In some implementations, the electrode and sensor monitoring / analysis command set (98) is executable by the processing unit(s) (80). The electrode and sensor monitoring / analysis command set (98) may be configured to receive output torque values ​​related to the applied torque, analyze the received torque values ​​to identify a screw engagement step in which the first electrode is screw-coupled to the second electrode, identify an end face engagement step in which the end face of the first electrode contacts the end face of the second electrode, and perform various other calculations described above. For these purposes, in various implementations, the command includes commands and / or logic for itself, and heuristics and metadata for itself.

[0063] Although the instruction set(s) (96) are depicted as residing in a single device, it should be understood that in other implementations, any combination of elements may be located on separate computing devices. Furthermore, FIG. 14 is intended more as a functional description of the various features present in a particular implementation than as a structural schematic of the implementations described herein. As will be recognized by those skilled in the art, items depicted separately may be combined and some items may be separated. The actual number of instruction sets and how features are assigned among them may vary from implementation to implementation and may depend in part on the specific combination of hardware, software, and / or firmware for the selected particular implementation.

[0064] Generally, routines executed to implement embodiments of the present invention, whether implemented as part of an operating system or a specific application, component, program, object, module, or sequence of instructions, or a subset thereof, may be referred to herein as “computer program code” or simply “program code.” Program code generally comprises computer-readable instructions that reside in various memory and storage devices of a computer at various times and, when read and executed by one or more processors of a computer, cause the computer to perform operations necessary to execute operations and / or elements that implement various aspects of embodiments of the present invention. Computer-readable program instructions for performing operations of embodiments of the present invention may be source code or object code written, for example, in assembly language or any combination of one or more programming languages.

[0065] Program code implemented in any of the applications / modules described herein may be distributed individually or collectively into various different forms of program products. In particular, the program code may be distributed using a computer-readable storage medium having computer-readable program instructions to enable a processor to perform aspects of the embodiments of the present invention.

[0066] Computer-readable storage media are inherently non-transient and may include volatile and non-volatile, and removable and non-removable types of media implemented by any method or technique for storing information such as computer-readable instructions, data structures, program modules, or other data. Computer-readable storage media may additionally include random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other solid-state memory technologies, portable compact disc read-only memory (CD-ROM), or other optical storage devices, magnetic cassettes, magnetic tapes, magnetic disk storage devices or other magnetic storage devices, or any other media that can be used to store desired information and can be read by a computer. Computer-readable storage media must not be interpreted as transient signals in themselves (e.g., radio waves or other propagating electromagnetic waves, electromagnetic waves propagating through transmitting media such as waveguides, or electrical signals transmitted through wires). Computer-readable program instructions can be downloaded from a computer-readable storage medium to a computer, another type of programmable data processing device, or another device, or to an external computer or external storage device via a network.

[0067] Computer-readable program instructions stored on a computer-readable medium may be used to instruct a computer, other types of programmable data processing devices, or other devices to function in a specific manner so as to produce or result in a device or manufactured article comprising instructions that implement the functions / operations specified in the flowcharts, sequence diagrams, and / or block diagrams illustrated and described herein. Computer program instructions may be provided to one or more processors of a general-purpose computer, a special-purpose computer, or other programmable data processing device to produce a machine, and instructions executed through one or more processors cause a series of computing operations to be performed to implement the functions and / or operations specified in the flowcharts, sequence diagrams, and / or block diagrams.

[0068] In certain alternative embodiments, the functions and / or operations specified in the flowcharts, sequence diagrams, and / or block diagrams may be rearranged, processed in series, and / or processed simultaneously without departing from the scope of the embodiments of the present invention. Furthermore, any of the flowcharts, sequence diagrams, and / or block diagrams may include more or fewer blocks than exemplified in accordance with the embodiments of the present invention.

[0069] The terms used herein are intended to describe only specific embodiments and are not intended to limit the embodiments of the invention. As used herein, singular forms (“a,” “an,” and “the”) are intended to include plural forms as well, unless the context clearly indicates otherwise. It will also be understood that when used herein, the terms “include” and / or “comprising” specify the presence of the stated features, integers, steps, actions, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, actions, elements, components, and / or groups thereof. Furthermore, to the extent that the terms “include,” “having,” “having,” “together,” and “constituting” or variations thereof are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.”

[0070] Although the present invention has been illustrated by the description of various embodiments and these embodiments have been described in considerable detail, it is not intended to limit the scope of the appended claims to such details or in any way. Additional advantages and modifications will be readily apparent to those skilled in the art. Therefore, the invention in broader aspects is not limited to the specific details, representative apparatuses and methods, and exemplary examples shown and described. Accordingly, deviations from such details may be made without departing from the spirit or scope of the general concept of the invention.

[0071] Since the invention has been described in detail with reference to its specific embodiments, it will become apparent that modifications and variations are possible without departing from the scope of the invention as defined in the appended claims.

Claims

Claim 1 An electrode coupling monitoring system for use with a device configured to apply torque to a first electrode to screw-couple a first electrode to a second electrode, wherein the device is configured to output torque values ​​related to the applied torque, and the system comprises: a controller, and the controller comprises: Receive torque values; Analyze the received torque values ​​above to identify the screw engagement step in which the first electrode is screw-coupled to the second electrode or was screw-coupled; An electrode coupling monitoring system configured to identify an end surface engagement step in which the end surface of the first electrode contacts or has contacted the end surface of the second electrode. Claim 2 An electrode coupling monitoring system according to claim 1, wherein the controller is configured to identify the screw engagement step by determining that the received torque values ​​exceed a predetermined value. Claim 3 An electrode coupling monitoring system according to claim 2, wherein the controller is configured to identify the start of the screw engagement step by determining that the received torque values ​​exceed the predetermined value, and the controller is configured to identify the end of the screw engagement step by identifying the start of the end face engagement step. Claim 4 In claim 2, the controller is configured to identify the coupling as a defective coupling if, during the screw engagement step, the received torque values ​​exceed a check value a predetermined number of times, and the check value is a coefficient of the predetermined value, an electrode coupling monitoring system. Claim 5 An electrode coupling monitoring system according to claim 1, wherein the controller is configured to identify the end face engagement step by determining that the received torque values ​​are within a predetermined percentage of the maximum torque that can be applied by the device. Claim 6 An electrode coupling monitoring system according to claim 5, wherein the controller is configured to identify the start of the end face engagement step by determining that the received torque values ​​are within the predetermined percentage, the controller is configured to determine the end of the screw engagement step corresponding to when the end face engagement step starts, and the controller is configured to determine the end of the end face engagement step when the received torque values ​​fall below a predetermined minimum value and are subsequently maintained below the predetermined minimum value for a predetermined time period. Claim 7 An electrode coupling monitoring system according to claim 1, wherein the controller determines a torque difference percentage, the torque difference percentage is a percentage difference between a maximum torque value during the end face engagement step and an average torque during the screw engagement step, and is configured to compare the determined torque difference percentage with a historical torque difference percentage value or values. Claim 8 In claim 7, the electrode coupling monitoring system is configured such that the controller transmits a notification when the determined torque difference percentage deviates sufficiently from the historical torque difference percentage value or values. Claim 9 An electrode coupling monitoring system according to claim 8, wherein, when the determined torque difference percentage deviates by at least 10% from at least one of the mean or median of the hysteresis torque difference percentages, the controller is configured such that the determined torque difference percentage deviates sufficiently from the hysteresis torque difference percentage values ​​or values. Claim 10 An electrode coupling monitoring system according to claim 7, wherein the controller is configured such that the hysteresis torque difference percentage is determined by considering the hysteresis torque difference percentage values ​​for couplings determined to be appropriate and not considering the torque difference percentage values ​​for couplings determined to be inappropriate. Claim 11 An electrode coupling monitoring system according to claim 1, wherein the controller is configured to determine as improper coupling operations the case where the torque difference, which is the difference between the maximum torque value during the end face engagement step and the average torque during the screw engagement step, is divided by the maximum torque value during the end face engagement step. Claim 12 An electrode coupling monitoring system according to claim 1, wherein the controller is configured to determine the time of the screw engagement step and transmit a notification when the determined time of the screw engagement step deviates sufficiently from at least one of the average or median value of the history values ​​of the screw engagement step times. Claim 13 An electrode coupling monitoring system according to claim 1, wherein the controller is configured to determine the time of the screw engagement step and the total assembly time, the total assembly time is the sum of the time of the screw engagement step and the time of the end face engagement step, the controller is configured to determine the percentage of the time of the screw engagement step compared to the total assembly time, and the controller is configured to transmit a notification if the percentage of the determined time of the screw engagement step is sufficiently low compared to at least one of the average or median value of the historical value of the percentage of the time of the screw engagement step. Claim 14 In claim 13, the electrode coupling monitoring system is configured such that the controller excludes any screw engagement step times determined from improper coupling operations from the history value of the screw engagement time. Claim 15 An electrode coupling monitoring system according to claim 1, wherein the controller determines the time of the end face engagement step and is configured to transmit a notification when the determined time of the end face engagement step deviates sufficiently from at least one of the average or median value of the history values ​​of the end face engagement step time. Claim 16 An electrode coupling monitoring system according to claim 1, wherein the controller is configured to determine the time of the end face engagement step and the total assembly time, the total assembly time is the sum of the time of the end face engagement step and the time of the screw engagement step, the controller is configured to determine the percentage of the end face engagement step time compared to the total assembly time, and the controller is configured to transmit a notification if the determined percentage of the end face engagement time deviates sufficiently from the average or median of the historical values ​​of the percentage of the end face engagement step time compared to the total assembly time. Claim 17 In claim 16, the electrode coupling monitoring system is configured such that the controller excludes any screw engagement step times determined from improper coupling operations from the history value of the end face engagement time. Claim 18 An electrode coupling monitoring system according to claim 1, wherein the device comprises a sensor configured to detect torque applied to the first electrode by the device to provide output torque values, the controller comprises one or more processors, the controller is configured to cause the device to stop applying any torque when the controller detects an improper coupling operation, and the controller is configured to add torque data for couplings determined as appropriate couplings to a history database. Claim 19 In claim 18, an electrode-coupled monitoring system further comprising the device configured to apply torque, wherein the sensor measures at least one of the pressure, current, or voltage of a hydraulic fluid. Claim 20 An electrode coupling monitoring system for use with a device configured to apply torque to a first electrode to screw-couple a first electrode to a second electrode, wherein the device is configured to output torque values ​​related to the applied torque, and the system comprises: a controller comprising one or more processors; at least one memory device operably coupled to the controller; and a data communication interface operably associated with the controller, wherein the at least one memory device, when executed by the controller, causes the controller to: To receive torque values; By analyzing the received torque values ​​above, the screw engagement stage is identified where the first electrode is screw-coupled to the second electrode or is in the process of being screw-coupled; An electrode coupling monitoring system comprising a plurality of program instructions for identifying an end surface engagement step in which the end surface of the first electrode contacts or contacts the end surface of the second electrode. Claim 21 A method for monitoring an electrode coupling process, comprising: receiving output torque values ​​related to the applied torque from a device configured to apply torque to a first electrode to screw-couple a first electrode to a second electrode, or from an associated sensor; and analyzing the received torque values ​​to identify a screw engagement step in which the first electrode has been screw-coupled to the second electrode or is being screw-coupled, and identifying an end face engagement step in which the end face of the first electrode has contacted or is contacting the end face of the second electrode. Claim 22 Computer-readable instructions stored in a non-transient storage medium, wherein the computer-readable instructions, when read and processed by a controller, cause the controller to: receive output torque values ​​related to the applied torque from a device configured to apply torque to the first electrode to screw-couple the first electrode to the second electrode, or from an associated sensor; and analyze the received torque values ​​to identify a screw engagement step in which the first electrode has been screw-coupled to the second electrode or is being screw-coupled, and to identify an end face engagement step in which the end face of the first electrode has contacted or is contacting the end face of the second electrode.

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