Optical Measurement of Ceramic Surfaces in High-Temperature Metallurgy
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Solution Overview
Problem
In metallurgical applications, refractory ceramic components with cylindrical surfaces face wear and growth issues, making it difficult to assess their geometry accurately due to high temperatures, leading to imprecise visual assessments and unreliable empirical values.
Innovation Solution
A method using a device with a 'cold part' and 'hot part' where the 'hot part' guides measuring beams to the surface, and a camera with a distance measurement system captures three-dimensional images of the cylindrical surface, employing a laser and mirror arrangement with heat-resistant coatings to withstand high temperatures, allowing for precise data collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual assessment with the eye is used to check cylindrical surfaces, then the inspection can be performed, but the measurement precision is extremely imprecise and only possible from a considerable distance
Solution Approach 1:
A measuring tube with a reflective surface at a 45-degree angle acts as an intermediary optical system. The camera is positioned in the cold part and directs light through the reflective surface to the cylindrical component surface in the hot part, enabling precise optical measurement without direct contact with the high-temperature zone.
Solution Approach 2:
The reflective surface creates an optical copy or image of the cylindrical surface, allowing the camera to capture precise geometric information indirectly. This optical copying mechanism enables accurate measurement while keeping the camera isolated from the harsh thermal environment.
2Adaptability or versatility
If hooks are used to scan surfaces, then remote monitoring is attempted, but the measurement precision remains very imprecise and leads to wrong empirical values
Solution Approach 1:
The mechanical hook scanning system is replaced with an optical measurement system. Light beams and reflective surfaces substitute for physical contact, eliminating the imprecision of mechanical scanning while maintaining remote inspection capability. The optical system provides non-contact, high-precision measurement of the cylindrical surfaces.
3Measurement precision
If measuring devices are placed in the hot area, then on-site inspection is possible, but the device reliability deteriorates due to high temperatures
Solution Approach 1:
The measuring system is segmented into two distinct parts: a cold part containing the camera and sensitive electronics positioned away from heat, and a hot part containing only the measuring tube and reflective surface that can withstand high temperatures. This segmentation allows precise measurement while protecting sensitive components from thermal damage.
Solution Approach 2:
The measuring tube and reflective surface serve as thermal intermediaries, transmitting optical measurements from the hot area to the cold area where the camera is located. This intermediary structure enables the system to bridge the thermal gap, allowing on-site measurement capability while maintaining device reliability by isolating sensitive components from high temperatures.
4Productivity
If empirical values are used for assessment, then maintenance decisions can be made, but the reliability of maintenance decisions is compromised due to completely wrong results
Solution Approach 1:
The system provides real-time optical feedback on the cylindrical surface geometry through captured images. This feedback mechanism enables accurate assessment of wear and growth, replacing unreliable empirical estimates with precise measurement data while maintaining efficient maintenance decision-making.
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 reliable detection and measurement of cylindrical surfaces, providing precise data for determining wear and necessary repairs or replacements, enhancing safety by preventing melt breakthroughs and improving the accuracy of maintenance decisions.
Implementation Method 1
the section of the measuring tube opposite the reflection surface is also translucent, for example open. The arrangement mentioned means that the reflection surface preferably runs at an angle of approximately 45° to the central longitudinal axis of the measuring tube
Implementation Method 2
The device for distance measurement comprises a laser or a diode, which directs an optical beam onto a mirror arranged in the measuring tube, which directs the beam through the transparent peripheral section of the measuring tube onto the part of the cylindrical surface
Data Source
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AI summary
The invention relates to a device for detecting and measuring cylindrical surfaces on refractory ceramic components in metallurgical applications.