Angled Scanner Head for Torpedo Ladle Lining Wear Measurement
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Solution Overview
Problem
The existing systems for measuring wear in the refractory lining of metallurgical vessels, such as torpedo ladles, are inefficient as they require frequent inspection and replacement, leading to operational interruptions and high costs, especially when dealing with molten metals in the steel industry.
Innovation Solution
A system that uses a scanner head mounted at an angle relative to the vertical axis of the container, scanning the lining from multiple positions to compare before and after operation measurements, allowing for precise determination of wear and enabling repair only when necessary, utilizing a rotating means or support lance for comprehensive scanning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If frequent inspection and replacement of the lining are performed, then the reliability of the vessel is improved, but the productivity and operational efficiency deteriorate due to operational interruptions
Solution Approach 1:
The system performs preliminary measurement and assessment of the lining condition before actual damage occurs. By continuously monitoring the lining thickness and condition, the system enables proactive maintenance planning, allowing the vessel to operate until the lining reaches a predetermined replacement threshold, thus avoiding unnecessary interruptions while preventing catastrophic failures
Solution Approach 2:
The system establishes a feedback loop by measuring the lining condition, comparing it with reference data, and providing information about wear progression. This feedback enables dynamic adjustment of maintenance schedules based on actual wear rates, optimizing the balance between reliability and productivity by replacing the lining only when actually necessary
2Measurement precision
If the vessel is cooled down and heated up for inspection, then the measurement accuracy is improved, but the loss of time and operational interruption increase
Solution Approach 1:
The system changes the measurement parameters by using laser scanning technology that can operate at various temperatures. The measurement process is adapted to work with the vessel in its current thermal state, eliminating the need for cooling and heating cycles. The system adjusts measurement parameters such as laser wavelength and scanning speed to compensate for thermal effects, maintaining accuracy without operational interruptions
Solution Approach 2:
The patent replaces mechanical contact-based measurement methods with optical laser scanning. This substitution eliminates the need for physical access to the lining interior and the associated cooling/heating requirements, allowing measurements to be performed quickly without thermal conditioning of the vessel
3Measurement precision
If a scanner head mounted at an angle is used to scan the lining, then the measurement precision is improved by covering more areas, but the device complexity increases
Solution Approach 1:
The system transitions from a single-point or limited-area scanner to a laser scanner that projects a fan-shaped beam covering a two-dimensional area. By mounting the scanner at an angle and using the fan-shaped beam geometry, the system achieves comprehensive three-dimensional coverage of the lining surface, measuring both radial thickness and circumferential position simultaneously, thus improving measurement precision without proportionally increasing device complexity
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
Enables precise measurement of wear in the lining, reducing unnecessary repairs and operational interruptions by providing accurate data for condition assessment, thus minimizing costs and improving operational efficiency.
Implementation Method 1
a laser scanner for measuring the contour of the lining
Data Source
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AI summary
A system and method for measuring the inner space of a container provides for the measurement of the wear of the lining of a container such as a torpedo ladle optionally while the ladle is still hot. The interior lining of the container is scanned by a scanner head from a first position in the container which is at an angle relative to the vertical axis of the container. The scanner head is placed in a second position in the container at an angle relative to the vertical axis of the container and from the second position the scanner head scans the portions of the interior lining of the container which were not scanned during the first position scan. By comparing the scanning measurements of the lining from the first position scan and the second position scan after the container has been loaded and unloaded with an initial reference measurement of the lining the wear of the lining can be measured.