Abnormality cause identification method and abnormality cause identification system

Abstract

The present invention provides an abnormality cause identification method and an abnormality cause identification system which are capable of quickly identifying a cause of an abnormality occurring in gunning of monolithic refractory. The present invention acquires, from a plurality of sensors, detection values of a plurality of state quantities related to the gunning of the monolithic refractory, and identifies, when an abnormal detection value is detected in the detection values acquired from the plurality of sensors, a cause of the occurrence of the abnormal detection value. For this purpose, a correspondence relationship between the cause of the occurrence of the abnormal detection value and the detection value of another state quantity other than the state quantity detected as the abnormal detection value is produced in advance and, when an abnormal detection value is detected in the detection values acquired from the plurality of sensors, the cause of the occurrence of the abnormal detection value is identified on the basis of the correspondence relationship.

Description

Method and System for Identifying Abnormal Cause

[0001] The present invention relates to a method and a system for identifying the cause of an abnormality that occurs during spray construction of monolithic refractories.

[0002] Spray construction of monolithic refractories is a construction method in which monolithic refractories are conveyed by compressed gas or the like and sprayed onto a construction target together with construction water, and can be broadly classified into wet spray construction and dry spray construction. Among these, wet spray construction is a construction method in which construction water is added to the spray material in advance, kneaded to form a slurry, the monolithic refractory is pumped, and a quick-setting additive or the like is added at the spray nozzle at the tip before spraying (for example, Patent Document 1). On the other hand, dry spray construction is a construction method in which monolithic refractories are conveyed by air in a dry state, and construction water is injected at the spray nozzle at the tip before spraying (for example, Patent Document 2). In addition, as an intermediate spray construction between wet spray construction and dry spray construction, there is also a construction method in which water is injected into the conveyance path for conveying the spray material (for example, Patent Document 3).

[0003] In any case, spray construction of monolithic refractories is a construction method in which monolithic refractories are conveyed by compressed gas or the like and sprayed onto a construction target together with construction water. However, the amount of conveying gas and the amount of added water vary depending on construction conditions such as the characteristics of the spray material, the status of the construction target, and the ambient temperature, so it is necessary to manage and check various construction conditions in order to obtain a high-quality constructed body. In addition, since construction conditions constantly change, constructors need to adjust the construction conditions according to the situation.

[0004] Japanese Patent Application Laid-Open No. 2011-169498, Japanese Patent Application Laid-Open No. 2007-8766, International Publication No. WO 05 / 121676

[0005] Conventionally, in the spray construction of monolithic refractories, the management, confirmation and adjustment of construction conditions have often relied on the experience and intuition of constructors. For example, incorrect adjustments may cause abnormalities such as blockage of spray materials in the conveyance path or failure of the spraying device. However, conventionally, since it has not been possible to quantitatively grasp the history of the constructor's judgment, the adjusted contents, and the change in the state quantity due to the adjustment, it took a great deal of time to identify the cause of the abnormality and perform subsequent recovery.

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

[0007] According to one aspect of the present invention, the following method for identifying the cause of an abnormality is provided. A method for identifying the cause of an abnormality in which detection values ​​of multiple state quantities relating to the spraying of amorphous refractory materials are obtained from multiple sensors, and when an abnormal detection value is detected among the detection values ​​obtained from the multiple sensors, the cause of the abnormal detection value is identified in advance by creating a correspondence relationship between the cause of the abnormal detection value and the detection values ​​of other state quantities excluding the state quantity detected as the abnormal detection value, and when an abnormal detection value is detected among the detection values ​​obtained from the multiple sensors, the cause of the abnormal detection value is identified based on the correspondence relationship.

[0008] According to another aspect of the present invention, the following abnormality cause identification system is provided: an abnormality cause identification system comprising: a detection value acquisition unit that acquires detection values ​​of a plurality of state quantities relating to the spraying work of amorphous refractory materials from a plurality of sensors; and an abnormality cause identification unit that identifies the cause of an abnormal detection value when an abnormal detection value is detected in the detection values ​​acquired by the detection value acquisition unit, wherein the abnormality cause identification unit is pre-inputted with a correspondence relationship between the cause of the abnormal detection value and the detection values ​​of other state quantities excluding the state quantity detected as the abnormal detection value, and the abnormality cause identification unit identifies the cause of the abnormal detection value based on the correspondence relationship when an abnormal detection value is detected in the detection values ​​acquired by the detection value acquisition unit.

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

[0010] A conceptual diagram showing an example of the device configuration of a spray application device for performing spray application of amorphous refractory materials. A conceptual diagram showing an example of a correspondence relationship in the present invention. A conceptual diagram showing another example of a correspondence relationship in the present invention. A conceptual diagram showing another example of a correspondence relationship in the present invention. A conceptual diagram showing another example of a correspondence relationship in the present invention. A conceptual diagram showing the system configuration of the abnormal cause identification system according to the present invention.

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

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

[0013] In this embodiment, detection values ​​of multiple state quantities related to the spray application of amorphous refractory materials by the spray application device X are obtained from the multiple sensors, and when an abnormal detection value is detected among the detection values ​​obtained from the multiple sensors, the cause of the abnormal detection value is identified. Specifically, a correspondence relationship is created in advance between the cause of the abnormal detection value and the detection values ​​of other state quantities excluding the state quantity detected as the abnormal detection value, and when an abnormal detection value is detected among the detection values ​​obtained from the multiple sensors, the cause of the abnormal detection value is identified based on the correspondence relationship.

[0014] Figure 2A shows an example of the above correspondence. Figure 2A shows the correspondence between the cause of an abnormal detection value (decrease in flow rate) detected by the flow sensor 17 that detects the flow rate of the conveyed gas A and the detection values ​​of other state variables. For example, explaining the correspondence along the top row of Figure 2A, if the detection value of the pressure sensor 21 that detects the pressure inside the material tank 2 is lower than the specified value, the detection value of the pressure sensor 16 that detects the secondary pressure of the pressure reducing valve 12 is lower than the specified value, and the detection value of the pressure sensor 14 that detects the source pressure of the conveyed gas A is lower than the specified value, then the cause is a decrease in the supply amount of conveyed gas A.

[0015] Figure 2B shows another example of the above correspondence. Figure 2B shows the correspondence between the cause of an abnormal detection value (pressure drop) when an abnormal detection value (pressure drop) is detected in the pressure sensor 14 that detects the source pressure of the transported gas A, and the detected values ​​of other state variables. For example, explaining the correspondence along the second row from the top in Figure 2B, if the detection value of the flow sensor 17 that detects the flow rate of the transported gas A is higher than the specified value, and the detection value of the pressure sensor 15 that detects the secondary pressure of the strainer 11 is at the specified value, then the cause of the problem is an abnormality in the pressure reducing valve 12.

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

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

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

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

[0020] X Spray application equipment A Conveyor gas B Spray material C Application water 1 Conveyor gas introduction route 11 Strainer 12 Pressure reducing valve 13 Solenoid valve 14 Pressure sensor 15 Pressure sensor 16 Pressure sensor 17 Flow sensor 2 Material tank 21 Pressure sensor 3 Material dispensing motor 31 Power sensor 4 Conveyor route (material hose) 5 Spray nozzle 6 Water injection route 61 Water injection pump 62 Pressure sensor 63 Flow sensor 100 Abnormality cause identification system 101 Detected value acquisition unit 102 Abnormality cause identification unit

Claims

1. An abnormality cause identification method for obtaining detection values ​​of multiple state quantities related to the spraying of amorphous refractory materials from multiple sensors, and identifying the cause of an abnormal detection value when an abnormal detection value is detected among the detection values ​​obtained from the multiple sensors, wherein a correspondence relationship is created in advance between the cause of the abnormal detection value and the detection values ​​of other state quantities excluding the state quantity detected as the abnormal detection value, and when an abnormal detection value is detected among the detection values ​​obtained from the multiple sensors, the cause of the abnormal detection value is identified based on the correspondence relationship.

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

3. An abnormal cause identification system comprising: a detection value acquisition unit that acquires detection values ​​of multiple state quantities related to the spraying of amorphous refractory materials from multiple sensors; and an abnormal cause identification unit that identifies the cause of an abnormal detection value when an abnormal detection value is detected in the detection values ​​acquired by the detection value acquisition unit, wherein the abnormal cause identification unit is pre-inputted with a correspondence between the cause of the abnormal detection value and the detection values ​​of other state quantities excluding the state quantity detected as the abnormal detection value, and the abnormal cause identification unit identifies the cause of the abnormal detection value based on the correspondence when an abnormal detection value is detected in the detection values ​​acquired by the detection value acquisition unit.

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

Images