Laser scanner assembly and method for measuring interior refractory lining of a vessel

Abstract

A self-contained laser scanner assembly is provided for measuring thickness of a refractory lining of a metallurgical vessel. The scanner assembly can include a shaft body having a proximal end, a distal end, and a middle segment positioned between the proximal and distal ends. A laser scanner, for measuring thickness of the refractory-lining of the metallurgical vessel, is positioned at the distal end of the shaft body. Operational equipment, including a cooling system, a battery, a wireless access point and / or a controller are disposed in a housing unit coupled to the shaft body at the proximal end of the shaft body. A heat protection shield is coupled to the shaft body between the housing and the middle segment of the shaft body. An interchangeable adaptor is configured to be coupled to the middle segment of the shaft body for allowing the shaft body to be removably attached to more than one type of a robotic arm used for the movement of laser scanners or a temperature probe, a sampling probe, or a camera. The interchangeable adopter allows a user to interchange the laser scanner assembly with a temperature probe, a sampling probe, or a camera.

Description

[0001] LASER SCANNER ASSEMBLY AND METHOD FOR MEASURING INTERIOR

[0002] REFRACTORY LINING OF A VESSEL

[0003] Field of Inventions

[0004] The inventions are generally related to devices, systems, and methods for characterization of refractory linings of vessels. More specifically, the inventions are related to self-contained laser scanning systems for measuring thicknesses of refractory linings of metallurgical vessels.

[0005] Background

[0006] In metallurgical arts, furnaces are used to heat a material, e.g., iron or steel. As one example, an Electric Arc Furnace is a furnace that heats material by means of an electric arc. An induction furnace differs by use of eddy currents. A ladle is a bucketshaped container or vessel used to transport and pour out molten metals. The inside surfaces of furnaces and ladles are lined with a refractory material for the protection of such vessels against high temperatures of the molten metal. Commonly used refractory materials include, by way of example, magnesia carbon brick, high alumina brick, aluminum magnesia carbon brick, aluminum magnesium castable, zircon refractory brick, and ceramic fiber. With use, the refractory linings are subject to wear and deposits caused by the molten metal. Accordingly, adequate maintenance and servicing of the refractory lining is needed to achieve continuous, efficient, and safe operation of the receptacle, and production of a high-quality material. When the refractory lining’s thickness degrades below an acceptable threshold depth, or when there is an overgrowth of deposits, the refractory lining is replaced, repaired, or replenished. Inspection of the refractory lining should be carried out when the vessel is at or near operating temperature to minimize operational costs that would otherwise be associated with cooling of the vessel before inspection of the lining. For the safety of steel workers and to increase manufacturing efficiency, laser scanning devices (e.g., high-speed lasers) have been used for obtaining and determining refractory thicknesses of hot vessels.

[0007] Laser scanners have been used in iron and steel ladles, Basic Oxygen Furnaces (BOFs), Argon-Oxygen Decarburization Vessels (AODs), Electric Arc Furnaces (EAFs), aluminum and copper smelting vessels, foundry furnaces, and torpedo-lade-cars and bottom blown furnaces (Q-BOP's) for determining the interior refractory profile and calculating the lining thickness. Refractory profile can be calculated by the transit time between emission and reception of the laser beam by the laser scanner. In other words, a distance between the refractory lining and the laser scanner in the direction of the emitted laser beam can be used to calculate the thickness of the refractory lining. Consecutive scanning can be performed to acquire and compare data for determining surface corrosion, erosion, and / or thickening caused by overgrowth of deposits. To accomplish high accuracy of the characteristics of the refractory lining, it is best to scan all or most of the surface of the refractory lining. However, due to the internal profile and internal geometrical constraints of the receptacle, the laser scanner may be unable to obtain a full view of the surface of interest. Robotic and mechanical manipulator arm systems, having a laser scanner capable of emitting beams at various angles, have been used to successively manipulate the laser scanner to capture a more comprehensive topography of the refractory lining.

[0008] While specially equipped laser manipulation systems provide significant advantages, including safety of steel mill workers, and have proven to be effective in measuring thickness of the refractory linings, the systems do bear many disadvantages. The investment in a laser robotic system is very expensive, with its use being limited to laser scanning. Other needed operational tools for refractory vessels (e.g., furnaces and ladles), such as temperature probes, sampling probes, and cameras for inspections, are performed by other manipulation systems, which are not compatible with the laser manipulation systems. In other words, multiple systems are currently being used to perform different tasks for a single vessel. Accordingly, there is a need for a laser device that can be readily interchangeable with other tools operated by a manipulation system, more specifically a robotic system. Moreover, different metallurgical plants or mills can have different systems. It will be advantageous to have a single laser device that is compatible with different systems and can be used in any metallurgical plant regardless of the type of system that is being used. It will also be advantageous for the laser device to be able to scan a comprehensive surface topography of the refractory lining. These, and other advantages of the inventions will be apparent from the descriptions provided herein.

[0009] Summary

[0010] In accordance with one embodiment, a self-contained laser scanner assembly for measuring thickness of a refractory lining of a metallurgical vessel is provided. The assembly comprises a shaft body having a proximal end, a distal end, and a middle segment positioned between the proximal and distal ends; a laser scanner, for measuring thickness of the refractory lining of the metallurgical vessel, positioned at the distal end of the shaft body; operational equipment, including at least one or a combination of a cooling system, a battery, a wireless access point, or a built-in controller disposed in a housing unit coupled to the shaft body at the proximal end of the shaft body; a heat protection shield coupled to the shaft body between the housing unit and the middle segment of the shaft body; and an interchangeable adaptor configured to be coupled to the middle segment of the shaft body for allowing the shaft body to be removably attached to more than one type of a robotic arm used for the movement of laser scanner, and wherein the interchangeable adopter further allows a user to interchange the laser scanner assembly with a temperature probe, a sampling probe, or a camera. In one embodiment, the self-contained laser scanner assembly additionally comprising a protective housing rotationally coupled to the shaft body, wherein the protective housing houses or is coupled to the laser scanner and provides rotational movement to the laser scanner. The head of the shaft body can be sized to allow the protective housing to be inserted to an entrance door of a vessel (e.g., slag door of a furnace).

[0011] In one embodiment, the measurement data from the laser scanner for measuring the thickness of the refractory lining can be transferred (e.g., wirelessly) to an external controller (or CPU). The cooling system comprising a holding tank that stores a cooling fluid. The holding tank is in sealed engagement with channels extending along an interior of the shaft body for circulating the cooling fluid to the laser scanner in a closed loop formation. A docking station can be included for receiving the laser scanner assembly. The docking station can be connected to the build-in controller and / or the external controller. The docketing station allows for the battery to be recharged and for the cooling liquid to be cooled below a threshold value. The built-in controller and / or the external controller can evaluate the thickness measurements and / or temperature of the refractory lining or provides information to a user about the thickness and / or temperature of the refractory lining. The middle segment of the shaft body can be at or about a center of mass of the laser scanner assembly.

[0012] In accordance with another embodiment, a method of measuring thickness of a refractory lining of a metallurgical vessel with the laser scanner assembly is provided. The method comprises using a robotic arm to insert the laser scanner of the self- contained laser scanner assembly into an entrance mouth or door of a metallurgical vessel (e.g., slag door of a furnace) for measuring the thickness of the refractory lining of the metallurgical vessel. The method can additionally include removing the laser scanner assembly from the robotic arm and replacing the laser scanner assembly with a temperature probe, a sampling probe, or a camera, followed by inserting the temperature probe, the sampling probe, or the camera into the entrance door of the metallurgical vessel. The temperature probe, the sampling probe, or the camera can be coupled to the robotic arm via an interchangeable adaptor that is configured to couple the laser scanner assembly to the robotic arm. The method can additionally comprise placing the self-contained laser scanner assembly on a docking station after taking measurements of the refractory lining to recharge the battery on the docking station, transferring data, and / or allowing a cooling fluid of the cooling system to cool.

[0013] Brief Description of Drawings

[0014] The drawings are not illustrated in scale.

[0015] Figure 1 A is a perspective view of an autonomous scanner assembly in accordance to one embodiment of the inventions.

[0016] Figure 1 B is a side view of an autonomous scanner assembly in accordance to one embodiment of the inventions.

[0017] Figure 1C is a top view of an autonomous scanner assembly in accordance to one embodiment of the inventions.

[0018] Figure 1 D is a distal front view of an autonomous scanner assembly in accordance to one embodiment of the inventions.

[0019] Figures 2A-2C illustrate various embodiments of the autonomous scanner system connected to a movement system (e.g., robotic movement system) for manipulation of the autonomous scanner system into and out of a vessel, and within the vessel.

[0020] Description

[0021] The described embodiments of the inventions are directed to a scanner assembly and system for use with metallurgical ladles, furnaces, and receptacles - referred to herein as vessels. The described embodiments of the scanner assembly and system can also be used with non-metallurgical vessels, including vessels used in high temperature manufacturing of materials for which there may be a need for a scanner. Particularly, the described embodiments of the inventions are directed to an autonomous scanner assembly and system, such as an autonomous laser assembly and system. The autonomous laser assembly can include a laser scanner for emitting a laser beam used to retrieve information or data for characterization of a refractory lining of vessels. The autonomous laser assembly can be self-contained to include operational components and equipment, such as at least one or a combination of electronics, wireless access point, controller or CPU, data processor, replaceable or rechargeable battery, cooling elements and capabilities (e.g., tank, pump, and cooling fluid), substitutable connectors or adaptors, or a heat protection shield. The scanner assembly and system can be configured to be easily interchanged with another tool of a movement system (e.g., robotic movement system or robotic arm or a mechanical movement system), such as a temperature probe (e.g., lance-holder for disposable temperature probe), a sampling probe (e.g., disposable sampling probe), and / or an imaging device (e.g., camera). The scanner assembly and system can be configured to be removably attachable to and easily detachable from more than one type of a movement system (e.g., robotic arm movement system or robotic arm or a mechanical movement system) that is used to control the movement and manipulation of the tools, including movement of tools into and out of a vessel, and manipulation of the tools to a multitude of different measuring positions within the interior chamber of the vessel.

[0022] As used herein “to characterize the target” or “characterize the refractory lining,” means to determine, measure, or calculate conditions of the target or refractory lining. The conditions can include the thickness of the target or refractory lining, or features, such as surface profile, topography, or irregularities with the target or refractory lining. Such characterization can be used for a variety of purposed, such as evaluating wear, damage, or structural failure points, assessing the remaining lifetime of the target or refractory lining, or determining if any repairs are needed. Target or lining characterization may also be used for other purposes, such as for determining the position of auxiliary devices used during manufacturing. In one embodiment, the condition can include temperature or surface temperature of the refractory lining.

[0023] As used herein a vessel is intended to include any type of container, furnace, or ladle used in the manufacturing process, including to heat (i.e. , subjecting to elevated temperatures) the metal or on-metallic material, or to contain and / or transport a molten metal or a non-metallic material. The nonmetallic materials can include any chemical that is being subjected to high or elevated temperatures. Examples of vessels that can be used with the embodiments of the present inventions include CONARC® furnaces, Basic Oxygen Furnaces (BOFs), Argon-Oxygen Decarburization Vessels (AODs), Electric Arc Furnaces (EAFs), aluminum and copper smelting vessels, foundry furnaces, and torpedo-ladle-cars and bottom blown furnaces (Q-BOP's). Preferable applications of the embodiments disclosed herein are for EAFs.

[0024] As used herein, a refractory lining can include one or more layers of a material or combination of materials used for the protection of the vessel . Non-limiting, illustrative examples of refractory material include magnesia carbon brick, high alumina bricks, aluminum magnesia carbon brick, aluminum magnesium castables, zircon refractory bricks, and ceramic fibers.

[0025] As used herein, the term “communication” means that a fluid, gas, signal, or data can flow, travel, pass, or be submitted (terms used interchangeably) from one component of the system to another component of the system, and / or to an auxiliary component or a completely different component not associated with the system. The communication can be direct or indirect. Direct means that fluid, gas, signal, or data travels from component A to component B (or between components A and B) without any intermediate or intervening components (e.g., component C). Indirect means that the fluid, gas, signal, or data travels from component A to component B (or between components A and B) with one for more intermediate or intervening components through which the fluid, gas, signal, or data also travels. With respect to the specification and claims, all communication is intended to mean either “direct” or “indirect” unless specifically designated as either “direct” or “indirect.” The electronic- type communication can be wired or wireless (e.g., Bluetooth, Wi-Fi, infrared, etc. networks).

[0026] The term “coupled,” “engaged,” “attached,” and “connected” are terms that are herein used interchangeably and are intended to mean the same. These terms can mean fixedly attached (i.e. , no movement) or movably attached. Fixedly attached mean that component A is permanently secured orfastened (e.g., welding, soldering, adhesive, physically bonded, screw, etc.) to component B such that components A and B cannot move relative to each other. Moveably attached means that component A can move relative to component B. The terms can also mean that one component can be detached or disconnected from the other component (e.g., friction fit, screw, via couplers, etc.). Disconnecting or detaching can be performed by the operation of the machine itself (e.g., by actuating or moving one component to engage or disengage with another component), or it can be performed by a user, or a maintenance provided (e.g., attached via a coupler, a screw, or friction fit connection where the user can disconnect the two components).

[0027] The term “coupled,” “engaged,” “attached,” and “connected” can also mean that component A is in communication with component B to allow gas (e.g., air or cooling gas) or a fluid (e.g., water or cooling fluid) to flow from component A to component B (or between components A and B), or for data or signals to pass flow from component A to component B (or between components A and B). The coupling, engagement, attachment, connection, or communication can be direct or indirect. Direct means that component A is in contact with or touching component B without any intermediary or intervening components being placed between components A and B. Indirect means that component A is in contact with or touching component B with one or more intermediary or intervening components placed in between components A and B (e.g., component A contacts component B via component C or that a single travels from component A to component B via component C). With respect to the specification and claims, all coupling, engagement, attachment, connection, or communication are intended to mean either direct or indirect unless specifically designated as either direct or indirect. With respect to the specification and claims, all connection is intended to mean either permanent or detachable (or removable) unless specifically designated as either permanent or detachable.

[0028] As used herein, the term “adjacent” takes its ordinary definition and means next to or adjoining. For example, when component A is said to be adjacent to component B, this means that (1 ) component A is in proximity of component B without component A touching component B; (2) component A is in surface contact with components B; or (3) a portion of component A overlaps (either with or without contact) a portion of component B. As another example, when component A is said to adjacent to an end of the component B, this means component A in directly on the end of component B or is close proximity to that location.

[0029] As used herein, “relative movement” or “movably connected” means where at least one element moves with respect to the other. Thus, for example, when it is said that component A is configured to move relative to component B, or component A is movably connected to component B, this is intended to include A moving and B being stationary, B moving and A being stationary, or both A and B moving. The movement can be, for example, linear and / or rotational, along a common or different axis, around a common or different axis, or in a hinged manner.

[0030] As used herein, “a sealed engagement” between component A and component B means that a fluid or gas is prevented from being discharged or leaked out from a junction where the assembled pieces are mated, under normal or intended operating and use conditions. As one illustrative example, a sealed engagement between component A and B can mean that a fluid discharged from component A into an inlet or opening of component B does not discharge or leak from a junction where component A connects with component B, under normal or intended operating conditions. As used herein, the singular forms “a”, “an,” and “the” are intended to include the plural forms and plural is intended to include singular, unless the context clearly indicates otherwise. Thus, connector or adaptor, for example, can include more than one connector or adaptor, unless otherwise specifically indicated that it is in either in single or plural form.

[0031] As used herein, the terms, “first, “second” etc. are used simply to distinguish one feature or element from another feature or element. Thus, a first feature or element discussed herein could be termed a second feature or element, and similarly, a second feature or element discussed herein could be termed a first feature or element.

[0032] As used herein, the term “about,” “approximately,” “substantially,” and “generally” are used to represent an amount, value, or degree that is close to the stated amount while still performing the same desired function or achieves the same result. The terms can refer to an amount, value, or degree that is within less than or equal to 10% of the stated amount, preferably less than or equal to 5% of the stated amount, and most preferably less than or equal to 1% of the stated amount. In one exemplary embodiment, “about” 90 degrees” includes any degree between 80 and 100 (i.e., 90 + / - 10%).

[0033] As used herein, the term “and / or” includes one or any combinations of one or more of the associated listed items.

[0034] The following description of the exemplary embodiments of the inventions refers to the accompanying drawings, where the same reference numbers in the drawings identify the same, similar, or equivalent elements. Figures 1 A-1 D illustrate an autonomous, self-contained scanner assembly 10. The scanner assembly 10 is used to obtain data or information for characterizing a target or refractory lining, including measuring wear or thickness of the refractory lining of a vessel. In one embodiment, the scanner assembly is also capable of measuring the temperature or surface temperature of the refractory lining. The scanner assembly 10 can be generally defined by an elongated shaft body 12 having a distal end (which is the vessel insertion end) and an opposing, proximal end. The shaft body 12 can be a metallic pole with inner channels 12’ that can withstand high mill and manufacturing temperatures. The inner channels 12’ can be used for circulation of a cooling fluid or gas and / or for housing wires of the electronic components. In one embodiment, the shaft body 12 can be a double or triple walled structure -- that is, for example, the shaft body 12 has an outer pole that houses an inner pole, that in turn can optionally house another pole. The spaces between the poles and the conduit running within the center most pole can be used for circulation of the cooling fluid or gas and to house wires and other mechanical and electronic components. The length of the shaft body 12 can vary, depending on its application and the size or depth of the vessel for which it is being used. The shaft body 12 can be constructed of sectional body segments that can be connected and disconnected to allow for adjustment of the length of the shaft body 12. The shaft body 12 can also have a telescopic-type construct for allowing its length to be expanded and retracted.

[0035] A scanner 14, such as a laser scanner 14, is couple to, incorporated into, or housed within a protective housing 16 that is coupled to the shaft body 12. The protective housing 16 can act as a rotational actuator or a turret to allow the scanner 14 to rotate with respect to the shaft body 12 for providing 360 degrees scanning or mapping capabilities. The protective housing 16 can be rotated with the use of any traditional motor system and gears. The rotary motion of the scanner 14 can be around a central longitudinal axis of the shaft body 12, extending from the proximal end to the distal end. The protective housing 16 can be rotationally coupled to the shaft body 10 via a shaft connector 18 that allows the protective housing 16 to spin around the central longitudinal axis in clockwise and / or counterclockwise directions.

[0036] In one embodiment, the scanner 14 can include laser emitters, sensors, optics, photodetectors, and other components as is well known in the art. Various sensors, optics, temperature probe (e.g., temperature pyrometer), and photodetector can also be incorporated into the protective housing 16. The laser emitter can be of the type that emits rapid pulses (e.g., pulsed infrared wavelengths) of laser light at a target or refractory lining surface. A wireless access point and / or a controller (or CPU) is in communication (e.g., wired or wireless) with the scanner 14. The built-in controller and / or an external controller (or CPU) receives data via a wired or wireless network from the scanner 14 and calculates the amount of time it took for each pulse to return from the target or refractory lining back to the scanner 14. That is, in one embodiment, the measurement data from the laser scanner for measuring the thickness of the refractory lining can be transferred to the built-in controller, can be transferred to an external controller, or can be transferred to the built-in controller which in turn transfers the data to external controller. The transfers can be via a wireless network, a wired network, or a combination of both, and the data can also include temperature data.

[0037] The built-in and / or external controller calculates the distance between the scanner 14 and the target or refractory lining with a high degree of accuracy. By repeating the laser emission process in quick successions, and by incorporating the orientation of the scanner 14 relative to the vessel, the built-in or external controller can characterize the target or refractory lining. For example, the controller can produce a thickness topographical map of the refractory surface. The scanner can also measure the temperature of the refractory lining. The built-in or external controller can compare changes between measured refractory thicknesses of the refractory lining, including comparisons made with a reference value. The controller can provide feedback to a user about the changes and possible conditions that may result in inadequate performance or the failure of the refractory lining.

[0038] The scanning lines of the laser define the “field of view.” The field if view of the laser beam should be as comprehensive as possible, to allow the scanner 14 to capture as much of the surface of the lining as possible. A wide-ranging field of view in combination with the manipulation of the movement system (e.g., robotic movement system or robotic arm or a mechanical movement system) within the vessel should allow the controller to characterize all or a majority of the target or the lining. Figures 1A-1 D illustrate a horizontal scanning line 20a (i.e. , linear to the longitudinal axis) and vertical scanning line 20b (i.e., orthogonal, 90 degrees, or about 90 degrees to the linear emission 20). Preferably, the laser scanner should also be able to emit at an obtuse angle (i.e., greater than 90 degrees) relative to the liner longitudinal emission, which is illustrated by scanning line 20c. In one embodiment, the viewing angle is about 120 degrees, with a range of about +92 degrees to about -28 degrees.

[0039] A middle segment 22 (Figure 1 B) of the shaft body 12 includes a connection junction 24 (Figure 1 B) configured to receive or be coupled to an arm of more than one type of a movement system (e.g., robotic movement system or robotic arm or a mechanical movement system) to allow the scanner assembly 10 to be used in conjunction with more than one type of a movement system regardless of the type or model. The laser scanner 14 can be configured to be removably attachable to and easily detachable from a variety of manipulator movement systems (e.g., robotic movement system or robotic arm or a mechanical movement system), including those that are used to control the movement of other tools.

[0040] Accordingly, the scanner or laser assembly 10 is configured to be easily interchangeable with another or existing tool of a manipulator movement system (e.g., robotic movement system or robotic arm or a mechanical movement system), such as, for example, a temperature probe (e.g., lance-holder for a disposable temperature probe), a sampling probe (e.g., disposable sampling probe), and / or an imaging device (e.g., camera). Interchangeable adaptors 26 (Figure 1 C) can be used to facilitate coupling of the middle segment 22 of the shaft body 12 to a variety of types and models of movement systems (e.g., robotic movement systems or robotic arm or a mechanical movement system). In an embodiment, the interchangeable adaptor 26 can be easily connect to and disconnected from the shaft body 12 and / or from the movement systems (e.g., robotic movement systems or robotic arm or a mechanical movement system). In some embodiments, the same interchangeable adaptor 26 used for the scanner or laser assembly 10 can be compatible with other tools, including a temperature probe (e.g., lance-holder for a disposable temperature probe), a sampling probe (e.g., disposable sampling probe), and / or an imaging device (e.g., camera), and can be easily connect to and disconnected from the other tools so as to allow a user to be able to interchangeably use the shaft body 12 and the other tools with the same movement systems (e.g., robotic movement systems or robotic arm or mechanical movement system). Alternatively, a different interchangeable adaptor 26 than the one used for the scanner or laser assembly 10 may have to be used with the other tools.

[0041] The selection of the interchangeable coupling elements 26 is based on the type and model of the movement systems (e.g., robotic movement systems or robotic arm or mechanical movement system). For example, if two different mills use different robotic movement systems, each mill can use a different adaptor 26 to easily make their robotic systems compatible with the laser assembly and system 10.

[0042] The middle segment 22 is between the distal and proximate ends or approximately in the middle of the shaft body 12. The middle segment 22 is preferably located at the center of the mass of the scanning assembly and system 10 or about adjacent to the center of the mass of the scanning assembly 10. The precise location of the middle segment 22 of the shaft body 12 depends on the length of the shaft body 12 and the weight and location of the components supported by the shaft body 12.

[0043] A heat protection shield 28 is coupled to the shaft body and in positioned between the middle segment 22 and the proximal end of the shaft body. The heat protection shield 28 can be stationary. In one embodiment, the position of the heat protection shield 28 can be adjustable - meaning, it can be moved by a user towards and away from the middle segment 22 of the shaft body 12. A housing, such as a control box enclosure unit 30 is coupled to shaft body 12, at or adjacent to the proximal end of the shaft body 12. The housing or control box enclosure unit 30 is coupled to the shaft body 12 at proximal side of and adjacent to the heat protection shield 28. The heat protection shield 28 protects the components of the housing or control box enclosure unit 30 from extreme radiation temperatures. The housing or control box enclosure unit 30 can house operational systems and components, including a cooling system 31 , battery 33, a wireless access point, a controller 35, and / or various other mechanical and electronic components (schematically depicted in Figure 1C). The mechanical and electronic components can include a motor system for rotating the protective housing 16; processor in communication with sensors; a pump for circulation of the cooling fluid or gas; and connection ports to recharge the battery, to communicate with the controller, and / or to replace or replenish the cooling fluid or gas. The cooling system 31 is in a sealed engagement with the shaft body 12 and allows for circulation of a cooling gas or fluid through the channel 12’ of the shaft body 12 to the scanner 14. The cooling system 31 can be self-contained to hold (in a tank) and circulate (by a pump) in a closed-circuit loop the cooling gas or fluid to and from the scanner 14. In one embodiment, the cooling system 31 can be coupled to an outside source for receiving and circulating a cooling gas or fluid. The battery 33 can be replaceable or rechargeable and supplies power to the scanner 14, the controller 35, and the various electronic and mechanical (e.g., motor for rotating the protective housing 16) components. The battery power should be sufficient for conducting one or more characterization operations. The wireless access point and / or controller 35 is in communication with the scanner 14 to receive and optionally store data from the scanner 14. The controller 35 can also be in communication with a second external controller (or CPU) for transmitting data or information to a user and / or controlling the operations of the scanner assembly and system 10 by the user. The scanner assembly and system 10 can be placed on a docking station for transfer of data, recharging of the battery, and / or addition or replenishment of the cooling gas or fluid.

[0044] Figure 2A, 2B, and 2C illustrate a method for use of the scanner assembly and system 10. Preferably, the scanner assembly and system 10 is an autonomous laser assembly as described above. Figures 2A-2C are described with reference to a metallurgical vessel (such as a furnace or a ladle). In some embodiments, the scanner assembly and system 10 can be used with non-metallurgical vessels, including vessels used in high temperature manufacturing of materials for which there may be a need for a scanner. A robotic arm 32 of a robotic movement system can be coupled to the middle segment 22 of the shaft body 12, preferably at or about the center of mass of the scanner assembly 10. The robotic arm 32 can be coupled to the shaft body 12 via the interchangeable adaptor 26. Accordingly, the same adaptor or a different adaptor will allow the same robotic arm to be used with a variety of other tools, including a temperature probe (e.g., lance-holder for a temperature probe), a sampling probe (e.g., disposable sampling probe), and / or an imaging device (e.g., camera). The scanner assembly 10 can be dismounted off the robotic arm 32 and replaced with a lance-holder of a temperature probe or disposable sampling probe, for example.

[0045] In one embodiment, the autonomous scanner assembly 10 is configured to be able to fit into an entrance mouth, preferable a slag door 36 of a metallurgical furnace (e.g., EAF) 34. More specifically, the protective housing 16 having the laser scanner 14 can be inserted into the slag door 36 and into the furnace 34. A slag door 36 is positioned on the side of the furnace shell with a tunnel area leading from the furnace interior, and an apron extending below the opening on the exterior of the furnace. The slag door is used for periodic tapping of slag by tipping the furnace, but it is also used for many other operations, including charging of additives, sample collecting, temperature measurement, insertion of burners and oxygen lances, and visual inspection of the furnace interior. For example, a slag door allows a ram device to remove excess slag from the molten metal bath in an electric arc furnace. Access through the slag door 36 is safer, more convenient, and maximizes production time, cost, and manufacturing efficiency. For example, an operator does not have to open the roof of the furnace - remove the electrodes positioned at the roof - to make a measurement, especially for CONARC® furnaces with continuous scrap feeding.

[0046] Once the laser scanner 14 is inserted through the entrance mouth or slag door 36 and into the vessel 34, the laser scanner 14 rotates, emitting rapid pulses (e.g., pulsed infrared wavelengths) of laser light at a refractory lining surface 38. By providing horizontal or linear 20a, vertical or orthogonal 20b, and obtuse 20c scanning lines, the laser scanner 14 will be able to capture the majority of the refractory lining surface 38. The obtuse angle 9 (between 20a and 20c of Figure 2C) should be greater than about 90 degrees, preferably greater than about 110 degrees, and most preferably greater than about 120 degrees. In one embodiment, the view angle can be, for example, 120 degrees with a range of +92 to -28 degrees. As best shown in Figure 2C, a negligible amount of a “blind spot” may be unavoidably present, which is the area untouched by the scanning lines. A controller (or CPU) can receive the data from the laser scanner 14 and calculates the amount of time it took for each pulse to return from the refractory lining surface 38. The controller calculates the distance between the laser scanner 14 and the refractory lining surface 38 with a high degree of accuracy. By repeating the laser emission process in quick successions, and by incorporating the orientation of the laser scanner 14 relative to the vessel 34, the controller can characterize the refractory lining surface 38. For example, the built-in or external controller can produce a thickness topographical map of the refractory lining surface 38. The built-in or external controller can compare changes between measured thicknesses of the refractory lining, including comparisons made with a reference value. The built-in or external controller can provide feedback to a user about the amount of wear, changes that may require the need for maintenance, or possible conditions that could lead to failure of the refractory lining 38 or the vessel shell.

[0047] In one embodiment, the laser scanner assembly and system comprises, or consists of, at least one of: A rechargeable battery to provide enough energy for one or more measuring operations; a wireless access point; a computer with solid state drive (SSD) memory, which temporarily stores the measurement data from the measuring head during measurement; cooling system including a tank with a cooling liquid, which serves as a closed loop system for the cooling of the laser during one or more measuring operations; or a heat protection shield. A mechanical adaptor is also provided that allows the laser assembly and system to be compatible with a variety of different types or models of robotic arms. Such adaptability would avoid the need for a dedicated robotic arm by allowing the laser assembly and system to be interchangeable with other probes that are put onto a mill robotic arm. This can make the system self- contained and gripped by any type of robotic arm or mechanical manipulator by using a specially designed mechanical adapter. The laser assembly of the present inventions can be used by any mill regardless of the robotic arm that the mill uses. The laser scanner does not require any external connections for energy, data exchange, or cooling during the laser measurement acts. It can operate completely self-sufficiently - that is, an autonomous working laser scanner arm that includes cooling device, electronics, rechargeable battery, and wireless data communication and has no external connections (e.g., for power, data, cooling), cabling, piping, etc. When the laser assembly and system is not connected to the robotic arm, its “dumbbell” or “bone” shaped designed allows it to be placed on a charging and communication tray with continuous cooling / charging / communication capabilities. The laser scanner is designed to perform at least one measurement autonomously. After the measurement is completed, the laser scanner can be placed on the charging / communication tray. In this parked position, the laser scanner assembly and system 10 can be in communication with a power supply to recharge the battery; a coolant supply to replenish or change the coolant (or alternatively to simply allow the cooling fluid to cool down); and data connections for transmission of data. The communication can be achieved by using adapters or can be wireless. After the measurement data has been transferred, the battery has been charged, and the coolant has been cooled down, the laser scanner is ready for the next hot measurement. The laser scanner can be used to measure refractory lining in an Electric Arc Furnace (EAF). Refectory linings protect the steel work structure of furnaces, ladles, boilers, vessels, ducting, and other equipment from extreme conditions, acting as a protective layer of insulation on the internal surface. The laser head is only immersed so far that it sees the entire furnace including the area around the entrance mouth or slag door. Most of the shaft body can reside outside of the vessel. The laser scanner is specially designed and useful for a CONARC® furnace, which consists of two similar furnace shells that are primarily magnesia carbon refractory lined.

[0048] The described embodiments of the scanner assembly and system can be used with non-metallurgical vessels, including vessels used in high temperature manufacturing of materials for which there may be a need for a scanner. In one embodiment, laser scanner assembly is used in a metallurgical mill for measuring thickness of a refractory lining of a metallurgical furnace. The robotic arm 32 can be used to insert the laser scanner 14 of the self-contained laser scanner assembly 10 into the slag door 36 of the metallurgical furnace 34 for measuring the thickness of the refractory lining of the furnace. The laser scanner 14 is rotated and pulses of laser are emitted for measuring the thickness and / or temperature of the refractory lining 38. The method can also include replacing the laser scanner assembly 10 with a temperature probe (e.g., lance-holder for disposable temperature probe), a sampling probe (e.g., disposable sampling probe), or a camera, followed by inserting the temperature probe, the sampling probe, or the camera into the entrance mouth or slag door 36 of the vessel 34. The temperature probe, the sampling probe, or the camera can be coupled by a user to the robotic arm 32 via the same or a different interchangeable adaptor 26 that is configured to couple the laser scanner assembly 10 to the robotic arm 32. The method can additionally comprise placing the self-contained laser scanner assembly 10 on a docking station after taking measurements of the refractory lining. On the docking station, the user can recharge the battery, transferring data from the built-in controller to a second, outside controller, and / or allowing the cooling fluid or gas of the cooling system to cool, replace the cooling fluid or gas, or replenish the cooling fluid or gas.

[0049] While several particular forms, variations, and embodiments of the inventions have been illustrated and described, it will also be apparent that various modifications can be made without departing from the scope of the inventions. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the inventions.

Claims

Claims1. A self-contained laser scanner assembly for measuring thickness of a refractory lining of a metallurgical vessel, comprising:(a) a shaft body having a proximal end, a distal end, and a middle segment positioned between the proximal and distal ends;(b) a laser scanner, for measuring thickness of the refractory lining of the metallurgical vessel, positioned at the distal end of the shaft body;(c) operational equipment, including at least one or a combination of a cooling system, a battery, a wireless access point, or a built-in controller, disposed in a housing unit coupled to the shaft body at the proximal end of the shaft body;(d) a heat protection shield coupled to the shaft body between the housing unit and the middle segment of the shaft body; and(e) an interchangeable adaptor configured to be coupled to the middle segment of the shaft body for allowing the shaft body to be removably attached to more than one type of a robotic arm used for the movement of laser scanners, wherein the interchangeable adopter further allows a user to interchange the laser scanner assembly with a temperature probe, a sampling probe, and / or a camera.

2. The self-contained laser scanner assembly of claim 1 , additionally comprising a protective housing rotationally coupled to the shaft body, wherein the protective housing houses or is coupled to the laser scanner and provides rotational movement to the laser scanner.

3. The self-contained laser scanner assembly of claim 2, wherein the protective housing of the shaft body is sized to allow the protective housing to be inserted to a slag door of a furnace.

4. The self-contained laser scanner assembly of claim 1 , wherein the controller receives and stores data from the laser scanner for measuring the thickness of the refractory lining.

5. The self-contained laser scanner assembly of claim 1 , wherein the laser scanner is in wireless communication with the controller or an external controller andprovides data to the controller or the external controller which in turn measures the thickness of the refractory lining and provides information to a user about the thickness of the refractory lining.

6. The self-contained laser scanner assembly of claim 1 , wherein the cooling system comprising a holding tank that stores a cooling fluid.

7. The self-contained laser scanner assembly of claim 6, wherein the holding tank is in sealed engagement with channels extending along an interior of the shaft body for circulating the cooling fluid to the laser scanner in a closed loop formation.

8. The self-contained laser scanner assembly of claim 1 , additionally comprising a docking station for receiving the laser scanner assembly, wherein the docking station allows for the battery to be recharged and for the controller or laser scanner to transfer data to an outside controller.

9. The self-contained laser scanner assembly of claim 1 , wherein the middle segment of the shaft body is at or about a center of mass of the laser scanner assembly.

10. The self-contained laser scanner assembly of claim 1 , wherein the laser scanner is additionally configured to take a surface temperature of the refractory lining.11 . A method of measuring thickness of a refractory lining of a metallurgical vessel with the laser scanner assembly of claim 1 , comprising: using a robotic arm to insert the laser scanner of the self-contained laser scanner assembly of claim 1 into an entrance mouth of a metallurgical vessel for measuring the thickness of the refractory lining of the metallurgical vessel.

12. The method of claim 11 , additionally comprising removing the laser scanner assembly from the robotic arm and replacing the laser scanner assembly with a temperature probe, a sampling probe, or a camera, followed by inserting the temperature probe, the sampling probe, or the camera into the entrance mouth of the metallurgical vessel.

13. The method of claim 12, wherein the entrance mouth is a slag door of an Electric Arc Furnace.

14. The method of claim 12, wherein the temperature probe, the sampling probe, or the camera is coupled to the robotic arm via an interchangeable adaptor that is configured to couple the laser scanner assembly to the robotic arm.

15. The method of claim 11 , additionally comprising placing the self-contained laser scanner assembly on a docking station after taking measurements of the refractory lining, and the method additionally comprises:(a) recharging the battery;(b) transferring data; and(c) allowing a cooling fluid of the cooling system to cool.

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