Jig for aligning soderberg electrode casings

Abstract

A jig for Soderberg electrode casing alignment and a method of aligning Soderberg electrode casings using a plurality of jigs. A plurality of jigs may be disposed about the circumference of an existing casing and a new addition casing may be lowered on to the jigs such that the plurality of jigs forms a funnel guiding the new addition casing against horizontal guides of each of the jigs. Each jig comprising horizontal guides and vertical guides, such as lips, for engaging with and aligning the existing casing and the new addition casing while maintaining a vertical gap between the casings.

Description

JIG FOR ALIGNING SODERBERG ELECTRODE CASINGSFIELD

[0001] The present invention relates to Soderberg electrode casings and more specifically to alignment of Soderberg electrode casings.BACKGROUND

[0002] The Soderberg electrode is a self-baking electrode used in electric furnaces that can be gradually built up and consumed while the furnace is in use. Electrode paste is used to form the Soderberg electrodes and may be for example, a mixture of calcined carbon aggregates, such as calcined anthracite, and a binder such as coal tar pitch. In order to form the Soderberg electrode, the paste is fed into a steel casing and is gradually lowered into the electric furnace where electrical resistance from electrode current, among other heat sources in the furnace, is used to heat and solidify (or bake) the electrode.

[0003] The use of these Soderberg electrodes in electric arc furnaces requires the ongoing and precise addition and alignment of new cylindrical steel tubes (“casings”) to the electrode column as the electrode is consumed into the furnace. An offset or gap is typically required between the existing casing and the new casing to allow access for internal welding. The resulting gap between casings makes proper alignment of these new casings difficult to achieve but has costly consequences when not achieved. Poor alignment may result in electrical arcing, paste bleeds, and slipping issues among other problems.

[0004] Conventionally, new casings were added using a large rounded apparatus that was positioned on top of the existing casing using a crane. This apparatus is heavy, requires multiple skilled workers to operate, is very time consuming to use, and frequently does not completely align the casings.

[0005] An apparatus for accurate and repeatable alignment for Soderberg electrode casings is therefore desired.BRIEF DESCRIPTION OF THE FIGURES

[0006] Figure 1 is an example Soderberg electrode casing.

[0007] Figure 2 is an embodiment of a jig as described herein.

[0008] Figure 3 is another embodiment of a jig as described herein.

[0009] Figure 4 is an embodiment of a jig as described herein engaged with Soderberg electrode casings.DETAILED DESCRIPTION

[0010] According to embodiments as described herein, an apparatus or “jig” for Soderberg electrode casing addition and alignment is provided. Correct alignment requires the position of each casing, as well as the spacing and rotation of the casings relative to one another to be correct. The jig according to embodiments as further disclosed herein may align the position, rotation and spacing of the casings correctly, is easy to handle and simple to use without highly skilled workers or a crane.

[0011] FIG. 1 provides an example Soderberg electrode casing 102. The shells 104 of the Soderberg electrode casing, are precision manufactured, however, the backing band 106 and fins 108 are typically imprecisely or roughly welded on to the casing shells 104. Conventional methods for aligning the casings use this backing band for alignment which causes imprecise alignment. In some cases, the backing band may be precision manufactured but it’s rough welding to the casing shells causes misalignment. Accordingly, the jig as described herein is configured to contact the precision manufactured casing shells, for example, the faces and edges of the casing shells, directly rather than the backing band as in previous methods.

[0012] A plurality of jigs may be used to align a first Soderberg electrode casing with a second Soderberg electrode casing. The plurality of jigs, for example, three or more, may be distributed around the upper circumference of a first casing and connected to the lower circumference of a second casing. The second casing may be lowered on to the jigs and effectively wedged between the plurality of jigs, the jigs being positioned to provide the correct alignment, as further described herein.

[0013] The jig according to embodiments as disclosed herein may comprise a first part and a second part. The first part may be, for example, the lower portion of the jig and may comprise a clamp. The clamp may be configured to engage with a first casing, for example, a lower or existing casing. The second part may be, for example, the upper portionof the jig and may comprise a support. The support may be configured to engage with a second casing, for example the upper, or new addition, casing. The upper portion and lower portion of the jig may be configured to both vertically and horizontally align the upper and lower casings while maintaining a gap between the upper and lower casings. In another embodiment, the clamp portion of the jig may be configured to engage with the upper or new addition casing while the support portion of the jig may be configured to engage with the existing or lower casing. Throughout this disclosure, the examples and embodiments will be detailed based on the configuration with the clamp portion of the jig configured to engage with the lower or existing casing and the support portion configured to engage with the upper or new addition casing, however, in each case, the opposite configuration may also be used.

[0014] FIG. 2 shows an example jig 200 according to an example embodiment of the invention as disclosed herein. The jig comprises an upper portion comprising a support 202 and a lower portion comprising a clamp 204. The lower portion also comprises a stability support 206 for additional horizontal alignment and stability. The clamp 204 comprises an inner arm 208 and an outer arm 210. The outer arm comprises a lip 212 for engaging a horizontal edge of a lower casing shell 214 and a horizontal guide 216, below the lip, for horizontally guiding the casing shell 214, for example by abutting against the casing shell face. The outer arm may also comprise a sloped edge 217 for guiding the casing shell towards the horizontal guide, for example as the jig is lowered on to the lower casing. The inner arm comprises an adjustable pin that may be fastened or wedged against a backing band 218 of the casing. The support 202, or upper portion of the jig, may comprise a single arm that engages with an upper or new addition casing 220. The arm comprises a lip 222 oriented in the opposite direction compared to the lip of the clamp such as to engage a horizontal edge of an upper casing shell, and a horizontal guide 224, above the lip, for horizontally guiding the upper casing shell. The lip 222 may be positioned a select distance away from the lip of the clamp when the support and clamp are attached to form the jig. For example, the distance between the lips may be selected to ensure that the casings vertically align while maintaining a vertical gap between the casings. The support may also comprise a sloped edge 225 for guiding the casing shell towards the horizontal guide, for example as the new addition casing is lowered on to the jig. The upper portion 202 and the lower portion 204 may be connected to one another via a pivot point 226 such that the upper portion and lowerportion may rotate relative to one another, for example, the upper portion may rotate relative to the lower portion. This rotation may allow the jig to be removed from the casings once alignment is complete.

[0015] The first clamp and first support of the jig as shown in FIG. 2 may each also have a complementary adjacent second support 302 and second clamp 304 as shown in FIG. 3. In an example, the first clamp and second clamp may be connected at a lower end, for example near the stability support by a fixed plate 309. In another example, the first clamp and second clamp may be connected by a rotatable pivot point in place of a fixed plate (not shown). The first clamp and first support set may be connected to the second clamp and second support set by a pivot point. For example, a pivotable joint 306 may connect the lower portions of the two adjacent supports as shown in FIG. 3. Each clamp / support set may therefore be pivotable or rotatable relative to the other clamp / support set. This rotation may allow the jig to be configured for various casing diameters. Each of the supports may also separately be rotatable relative to its respective clamp such as to allow the jig to be disengaged from the casings after alignment. For example, a user may rotate the support using a handle 308, such that the support rotates relative to the clamp, and disengages from an upper casing. This process allows the jig to be removed from between the casings after the casings have been aligned. A user may rotate one support at a time relative to its respective clamp, or both supports at the same time relative to each of their respective clamps, in order to disengage the jig from the casings. Any rotatable features in the jig may be equipped with a locking mechanism to avoid unintended rotation during use.

[0016] After alignment of the casings, in an embodiment, the upper portion of the jig comprising the support and second support (for example, 302 in FIG. 3), may be rotated such that each of the support and second support rotate relative to the clamp and second clamp (for example, 304 in FIG. 3) on the lower portion of the jig, respectively. This allows for room for the entire jig to pivot inwards towards the casings thereby releasing the clamp and second clamp on the lower portion of the jig. Once the clamp and second clamp are released, the jig may be lifted upwards and away from both casings.

[0017] The lower portion of the jig may comprise a clamp. The clamp may comprise an outer arm and an inner arm. The outer arm may comprise a horizontal and vertical guide for aligning a casing. For example, when the clamp is configured to engage with a lowercasing, the outer arm may comprise a lip, wherein the top horizontal edge of the casing shell, for example a precision manufactured edge of the casing shell, abuts against the lip. The horizontal portion of the lip may rest on top of the horizontal edge of the casing, to provide vertical alignment for at least a portion of the lower casing. The precision manufactured face of the casing may also abut against a horizontal edge forming a horizontal guide of the clamp, for horizontal alignment. The clamp may be designed to not obstruct the internal fins of the upper casing thereby allowing the upper casing to be rotated into position as needed relative to the lower casing.

[0018] In an example, the outer arm and inner arm of the clamp may form a gap for receiving the casing. The inner arm may comprise an adjustable pin. The adjustable pin may be vertically offset from the horizontal guide of the outer arm. The pin may be tightened or may be spring loaded, such as to abut against the backing band that is welded to the casing shell which in turn may force the casing shell, for example the outer face of the casing shell, to abut against the horizontal guide of the outer arm. Contact of the pin of the inner arm against the backing band does not compromise alignment of the casings as the outer arm horizontal guide only contacts the face of the casing shell without contacting the backing band. The lip of the outer arm may comprise, for example, a sloped upper edge and a horizontal lower edge that meet at a point or corner. The horizontal lower edge may act as a vertical guide by abutting against the horizontal edge of the casing shell. The horizontal guide may be below the lip and may be accompanied by a sloped edge leading to the horizontal guide for guiding the casing shell into the correct horizontal alignment by abutting the casing shell against the horizontal guide. The corner of the lip may abut or rest in the corner formed by the backing band and the casing shell, however the alignment of the casing is dictated by contact of the horizontal edge of the lip and the horizontal guide with the casing shell, such as a precision manufactured casing shell, and not by any points of contact with the backing band. The combination of the adjustable pin, for example a vertically offset adjustable pin, and the sloped edge of the horizontal guide may attribute to the clamping action of the jig when the jig is installed on to the lower or existing casing.

[0019] The lower portion of the jig, in some embodiments, may also comprise an additional stability support for added horizontal alignment and stability. For example, the stability support may be configured to engage with a face of the casing shell, similar to thehorizontal support. The stability support and the horizontal guide of the clamp are vertically aligned such that they can work together to horizontally align the casing by abutting against the face of the casing shell. The lower portion of the jig may further comprise handles 310 (see FIG. 3), for example ergonomic handles that may be used as lifting points for manual handling of the jig.

[0020] The upper portion of the jig may comprise a support. The support may comprise a lip oriented in the opposite direction compared to the lip on the clamp portion of the jig. For example, the lip may comprise a sloped lower edge and a horizontal upper edge that meet at a point or corner. The horizontal upper edge of the lip of the support is parallel to the horizontal edge of the lip of the clamp such as to vertically align the upper and lower casings. For example, the horizontal upper edge of the lip of the support may act as the vertical guide abutting against the lower horizontal edge of the new addition casing shell, while the horizontal lower edge of the lip of the clamp may act as a vertical guide abutting against the upper horizontal edge of the existing casing shell.

[0021] When a plurality of jigs is engaged about the circumference of the existing casing, the lip of the clamp of each jig contacts the horizontal edge, for example a precision manufactured horizontal edge, of the lower casing at precisely the same elevation, thereby ensuring the rest of the jig, and in particular, the lip of the support of each of the plurality of jigs is vertically aligned such that the upper casing that rests on the lips of each of the supports is vertically aligned as well. The support also comprises a horizontal guide similar to the clamp portion of the jig, however the horizontal guide of the support portion is located above the lip of the support such as to abut and horizontally align the precision manufactured face of the upper or new addition casing. The horizontal guide of the support may be accompanied by a sloped edge which can help guide the casing to the horizontal guide such that the casing shell face abuts against the horizontal guide for correct horizontal alignment.

[0022] FIG. 4 is an example of a jig according to embodiments as described herein engaged with a lower or existing casing shell 402 and an upper new addition casing shell 404. The casing shell of each casing may be precision manufactured and provides the contact points needed for the jig, or a plurality of jigs, to align the casings. The clamp portion of each jig may be engaged with the existing casing by abutting a lip 406 of the jig against a top edge 408 of the casing shell. The clamp portion of the jig also comprises a horizontalguide 410 that abuts against the wall or face of the existing casing shell 402. The adjustable pin 412 of the clamp portion of the jig may be vertically offset from the horizontal guide and wedged against the backing band 414 of the lower casing such as to clamp the casing shell and backing band in the gap between the inner arm and outer arm of the clamp. The backing band may be roughly or non-precisely welded against the casing shell without compromising the alignment of the casings because the precision manufactured portions of the casing shells, for example the walls and edges, may be used to vertically align the casing against the lip and horizontally align the casing against the horizontal guide of the clamp and support of the jig, without reliance on the position or location of the backing band. For example, the support portion of the jig may be engaged with the new addition casing by abutting a lip 416 against a bottom precision manufactured edge 418 of the new addition casing shell, and by a horizontal guide 420 that abuts against the precision manufactured wall or face of the new casing shell 404.

[0023] Each clamp may be complemented by an adjacent clamp as described above. The adjacent clamp may engage with the lower casing in the same manner as the first clamp. The adjacent clamp may be connected to the first clamp by a fixed plate corresponding to a predetermined casing diameter or may be connected to the first clamp about a pivot point that can adjust the rotation of each clamp relative to the other based on a desired casing diameter or size.

[0024] The jig according to embodiments as described herein may be configured to engage with a lower casing, for example a pre-existing casing, and an upper casing, for example a new addition casing. A user may secure the lower clamp portion of the jig against the lower casing. Each casing may comprise, for example, a backing band that is roughly or imprecisely welded to the precision manufactured casing. In some cases, the backing band may be precisely welded, however this is infrequent. The backing band may extend above the upper or lower edge of the casing shell such that only a portion of the backing band is overlapping with, and welded to, the casing shell. The jig may be positioned on the lower casing by sliding the top of the backing band into the gap formed between the inner arm and outer arm of the clamp, for example, the gap formed between the adjustable pin of the inner arm and the lip of the outer arm of the clamp portion of the jig. The adjustable pin may be adjusted to wedge the backing band between the adjustable pin and the corner formed bythe lip. Simultaneously, the precision manufactured casing shell face may abut against the horizontal guide, wherein the horizontal guide may apply an equal but counter force against the casing shell as the adjustable pin applies against the backing strip, thereby wedging the casing shell and backing strip between the inner arm and outer arm of the clamp. The horizontal edge of the casing shell abuts against the horizontal edge of the lip of the clamp due to gravity. For example, the weight of the second or upper casing when engaged with the upper portion of the jig may be used to force the lip of the clamp portion against the top of the precision manufactured horizontal edge of the casing shell. In this way, the lip of the clamp provides vertical alignment of the casing, and the horizontal guide provides horizontal alignment of the casing, without any reliance on the position of the backing band, which may be imprecisely welded to the casing shell. Once the lower portion of the jig is secured, the upper portion can be attached. In another embodiment, the upper portion of the jig may already be attached to the lower portion before the jig is secured on to the lower casing.

[0025] The upper or new casing can be lowered on to a plurality of jigs disposed about the circumference or, for example around the outline of the lower casing if the casing is not cylindrical, such that the precision manufactured face of the new casing shell is guided via the sloped edge of the support towards the horizontal guide of the support of each of the plurality of jigs. Lowering of the upper casing stops when the bottom horizontal edge of the casing shell contacts the lip of the support of each jig such that the bottom edge of the casing shell and the face of the casing shell are each abutting the lip (vertical guide) and horizontal guide of the support, respectively. Due to gravity and the weight of the upper casing, a natural clamping action occurs that also secures the lower existing casing shell against the horizontal and vertical guides of the clamp.

[0026] In an example, the jig may be made light and the handles on the lower portion of the jig may be configured to be ergonomic to provide easy handling by users. The jig may also comprise a hook attached to the upper or lower portion of the jig that may be used for hanging or storage when the jig is not in use.

[0027] A process for aligning Soderberg electrode casings is provided herein. The method may comprise engaging a plurality of jigs about the circumference of upper and lower casings. For example, three or more jigs may be disposed around the circumference of a lower or existing casing as an upper or new casing is lowered on to the jigs such that avertical space is formed between the upper and lower casings when the casings are secured on the jigs. The plurality of jigs, for example as disclosed herein, may comprise an upper lip and a lower lip comprising horizontal parallel edges for contacting horizontal edges of each of the upper and lower casing shells, respectively. Each of the upper lip and lower lip may be vertically aligned. Each of the jigs may further comprise (i) an adjustable pin opposite and which may be vertically offset from, the lower lip to form a clamp, and (ii) a horizontal guide above the upper lip and a second horizontal guide below the lower lip. The method may comprise vertically aligning the upper and the lower casings by resting the lower lip on a precision manufactured horizontal edge of the lower casing shell and engaging a precision manufactured horizontal edge of the upper casing shell against the upper lip as the upper casing is lowered into place. The method further comprises horizontally aligning the lower casing with the upper casing by clamping a precision manufactured casing shell of the lower casing against the second horizontal guide without contacting a backing band of the lower casing against the horizontal guide, and abutting a precision manufactured casing shell of the upper casing against the horizontal guide without contacting a backing band of the upper casing against the horizontal guide. As the upper casing is lowered onto the jigs disposed about the upper edge of the lower casing, the sloped edges of the horizontal guide of the supports of each jig form a type of funnel or wedging effect that secures the upper casing into the exact required alignment. The plurality of jigs work together to maneuver the new casing into the correct alignment relative to the lower casing based on the horizontal and vertical (lip) guides of the support of each jig.

[0028] The jig and method as described herein align Soderberg electrode casings based on portions of each casing shell, for example precision manufactured portions, rather than based on a backing band as in conventional methods. In particular, the backing band may be roughly welded or imprecisely attached to the casing shells which would compromise alignment if relied upon.

Claims

CLAIMS:We claim:

1. A jig for Soderberg electrode casing alignment, the jig comprising, a clamp configured to engage with a first Soderberg electrode casing, the clamp comprising, an outer arm and an inner arm for retaining therebetween a portion of the first casing, wherein the outer arm and inner arm define a gap in the clamp for receiving the casing, and wherein the outer arm provides a first horizontal guide by abutting against a face of the first casing; and, a first lip in the outer arm, the first lip configured to rest against a horizontal edge of the first casing; and, a support configured to engage with a second Soderberg electrode casing, the support comprising, an arm, wherein at least a portion of the arm provides a second horizontal guide by abutting against a precision manufactured face of the second casing; and, a second lip configured to rest against a horizontal precision manufactured edge of the second casing, wherein the first lip and the second lip are distanced from one another by a select amount, and wherein the first horizontal guide and the second horizontal guide are positioned to horizontally align a portion of the first casing face with a portion of the second casing face.

2. The jig according to claim 1 comprising one or more of a second clamp adjacent to the clamp, and a second support adjacent to the support.

3. The jig according to claim 2 wherein the second support is rotatably connected to the support about a pivot point therebetween.

4. The jig according to claim 2 or 3 wherein the support is rotatable relative to the clamp, and the second support is rotatable relative to the second clamp.

5. The jig according to claim 3 or 4 further comprising one or more locking mechanisms to prevent rotation.

6. The jig according to any one of claims 2 to 5 wherein the support and / or the second support is configured to rotate relative to the clamp and / or the second clamp, respectively, to disengage the second lip from the edge of the second casing.

7. The jig according to any one of claims 2 to 6 wherein the second clamp is connected to the clamp via a fixed plate or a pivot point, and wherein the fixed plate corresponds to a predetermined casing diameter.

8. The jig according to claim 7 wherein the second clamp is connected to the clamp via the pivot point, and the clamp and the second clamp can be rotated relative to each other.

9. The jig according to any one of claims 2 to 8 wherein the outer arm of the clamp and / or an outer arm of the second clamp comprise a sloped edge for horizontally guiding the first casing.

10. The jig according to any one of claims 2 to 9 wherein the arm of the support and / or the arm of the second support comprises a sloped edge for horizontally guiding the second casing.

11. The jig according to any one of claims 2 to 10 wherein the outer arm of the clamp further comprises a stability support configured to engage with the face of the first casing.

12. The jig according to claim 11 wherein the stability support, the first horizontal guide and the second horizontal guide are vertically aligned and the first lip is between the second lip and the stability support when the clamp and the support are connected.

13. The jig according to any one of claims 2 to 12 wherein the second support is attachable to and detachable from the second clamp.

14. The jig according to any one of claims 1 to 13 wherein the support is attachable to and detachable from the clamp.

15. The jig according to any one of claim 1 to 14 wherein the inner arm of the clamp comprises an adjustable pin that is vertically offset from the first horizontal guide.

16. A Soderberg electrode casing alignment system, the system comprising a plurality of jigs in accordance with any one of claims 1 to 15.

17. A method for aligning Soderberg electrode casings, the method comprising, engaging a plurality of jigs about the circumference of upper and lower casings such that a vertical space is formed between the upper and lower casings and wherein each of the plurality of jigs comprises an upper lip and a lower lip that are vertically aligned and each of the jigs further comprises (i) a pin opposite from the lower lip to form a clamp, and (ii) a first horizontal guide below the lower lip and a second horizontal guide above the upper lip; vertically aligning the upper and the lower casings by resting the lower lip on a horizontal edge of the lower casing and engaging a horizontal edge of the upper casing against the upper lip; and, horizontally aligning the lower casing with the upper casing by abutting a lower casing face of the lower casing against the first horizontal guide, and abutting an upper casing face of the upper casing against the second horizontal guide.

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