Accelerated Sensor Unit Projection for High-Temperature Liquid Measurement
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Solution Overview
Problem
Current methods for determining parameters of high temperature liquids, such as molten metal in electric arc furnaces, are invasive, require manual intervention, lead to unreliable measurements, and introduce contaminants, while existing automated systems are costly and prone to damage.
Innovation Solution
A method using a lightweight sensor unit accelerated by means other than gravity, allowing it to be introduced through existing openings in the metallurgical vessel, minimizing exposure time and reducing the need for lances, with a system comprising acceleration means to control the sensor's immersion depth and angle for precise measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a lance assembly is used to introduce a probe into molten metal, then measurement capability is achieved, but the operation requires manual intervention and causes splashing and safety hazards
Solution Approach 1:
The probe is designed to be self-introducing by utilizing the pressure difference between the atmosphere and the molten metal bath. The probe automatically immerses itself into the melt without requiring manual lance operation, thereby eliminating splashing and safety hazards while maintaining measurement capability
Solution Approach 2:
The manual mechanical lance assembly is replaced by a pressure-driven automatic insertion mechanism. The probe uses pressure differential (atmospheric pressure vs. molten metal pressure) to achieve automatic immersion, replacing the need for manual mechanical operation
2Object-affected harmful factors
If the probe is immersed slowly into the melt, then safety is improved, but the probe burns prematurely and measurements become false
Solution Approach 1:
The immersion speed parameter is optimized to a specific range that balances two competing requirements: fast enough to prevent premature burning but slow enough to ensure accurate measurement. This parameter optimization resolves the contradiction between immersion speed and probe durability
3Ease of operation
If the opening in the vessel is kept free of blockages, then probe insertion is enabled, but the opening requires maintenance and is prone to heat and mechanical damages
Solution Approach 1:
The probe insertion function is extracted from the main vessel opening system. By using a separate, dedicated insertion path through the slag layer, the main opening does not need to be kept free of blockages, reducing maintenance requirements and exposure to heat and mechanical damage
Solution Approach 2:
The slag layer serves as an intermediary medium through which the probe passes to reach the molten metal. This intermediary path protects the main vessel opening from direct exposure to molten metal and reduces the need for keeping the opening clear
4Measurement precision
If a new probe is fitted on a lance after every measurement, then measurement accuracy is maintained, but the process time increases and measurement frequency decreases
Solution Approach 1:
The probe is designed as a disposable self-service element that is automatically inserted, used, and discarded in a single operation. This eliminates the time-consuming process of refitting probes and maintains measurement accuracy without reducing measurement frequency
Solution Approach 2:
The probe is pre-positioned and ready for automatic insertion before each measurement cycle begins. This preliminary preparation eliminates setup time and enables continuous high-frequency measurements with consistent accuracy
5Measurement precision
If the slag door is opened to insert a lance, then measurement access is achieved, but energy is wasted due to cold ambient air intake and the process is disturbed
Solution Approach 1:
The measurement access function is extracted from the main slag door opening. By creating a separate access path through the slag layer, the main slag door remains closed, preventing cold ambient air intake and energy loss while still enabling measurement access
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables non-invasive, high-frequency, and reliable parameter determination with reduced equipment and human intervention, minimizing contamination and energy waste, suitable for continuous operation in various metallurgical vessels.
Implementation Method 1
providing acceleration means above the surface of the high temperature liquid, wherein the acceleration means is adapted to increase the speed of the sensor unit
Data Source
Figure 1~2
Figure 3A~3B
Figure 4A~4B
AI summary
The present invention relates to a method for determining at least one parameter of a high temperature liquid with a sensor unit and a system to carry out the method. A measuring probe releasably carrying the sensor unit is provided to acceleration means, which accelerates the sensor unit after separation from the measuring probe. The sensor unit is projected in the direction of the high temperature liquid, immersed under the surface and the parameter of interest is measured. The invention further relates to a device comprising acceleration means suitable to carry out the inventive method and a metallurgical vessel comprising an inventive system or an inventive device.