High-Temperature Liquid Measurement Using Compact Sensor Acceleration
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Solution Overview
Problem
Current methods for determining parameters of high temperature liquids, such as molten metal, are invasive, require manual intervention, and result in unreliable measurements due to uncontrollable immersion and exposure to harsh environments, leading to increased costs and safety risks.
Innovation Solution
A method using a sensor unit accelerated by means other than gravity, allowing for controlled immersion into the liquid through a compact acceleration path, minimizing exposure time and material introduction, and utilizing existing vessel openings for non-invasive measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a lance assembly is used to manually insert a probe into the molten metal, then the sensor can be positioned close to the melt surface, but the operation requires interrupting vessel operation, causes splashing, and creates safety risks
Solution Approach 1:
The patent replaces the manual mechanical lance assembly with an automated drop-in sensor system that utilizes gravitational force and controlled release mechanisms. The sensor is dropped through a sealed opening without requiring manual intervention, eliminating safety risks associated with operator exposure to molten metal while maintaining measurement precision through controlled immersion depth.
Solution Approach 2:
The drop-in sensor system is designed to be self-deploying, utilizing its own weight and a simple release mechanism to immerse itself into the molten metal. The sensor automatically achieves proper immersion depth without external assistance, eliminating the need for interrupting vessel operation or manual lance manipulation, thus improving both safety and operational continuity.
2Ease of operation
If the probe is immersed slowly to ensure safety, then operator safety is improved, but the probe burns prematurely and measurements become false
Solution Approach 1:
The patent replaces controlled manual lowering with a free-fall immersion mechanism. The sensor is released and accelerates under gravity to achieve rapid immersion before the protective coating decomposes, ensuring both operator safety (no manual exposure) and measurement reliability (fast immersion prevents premature burning).
Solution Approach 2:
The sensor is designed to rush through the protective slag layer quickly by utilizing gravitational acceleration. This rapid passage through the harsh environment minimizes exposure time and prevents premature degradation of the sensor, ensuring reliable measurements are obtained before the sensor burns up.
3Duration of action of moving object
If the probe is not immersed deep enough to avoid excessive burning, then sensor lifespan is improved, but the temperature becomes unstable and measurements are unreliable
Solution Approach 1:
The patent optimizes the sensor design parameters including mass, dimensions, and material composition to achieve the right balance. The sensor is sufficiently massive to reach stable measurement depth quickly but not so massive that it requires prolonged exposure, thus achieving both adequate lifespan and measurement stability through parameter optimization.
Solution Approach 2:
The patent uses disposable sensors with protective coatings that replicate the properties of the molten metal environment. These sensors are designed to survive long enough to obtain reliable measurements and then are discarded, eliminating the need to balance lifespan extension with measurement stability for reusable sensors.
4Reliability
If a disposable probe is used after every measurement, then measurement reliability is improved, but additional components and process steps are required, lengthening the time interval between measurements
Solution Approach 1:
The patent extracts only the essential sensing function from the probe system, using simple disposable sensors without complex lance assemblies. This minimalistic approach reduces the time required to deploy and replace sensors, increasing measurement frequency while maintaining reliability through the disposable nature of the sensors.
Solution Approach 2:
The patent employs inexpensive disposable sensors that can be quickly replaced. The low cost and simple design of these single-use sensors enable frequent replacement and deployment, increasing measurement frequency while ensuring each measurement is performed with a fresh, reliable sensor.
5Ease of operation
If a large opening is made in the vessel for lance insertion, then probe access is improved, but the opening must be kept free of blockages and is prone to heat and mechanical damages
Solution Approach 1:
The patent changes the dimensional approach by using a vertical drop-in mechanism through a small opening rather than horizontal lance insertion through a large opening. The sensor falls vertically through a minimal opening, reducing the area exposed to heat and mechanical damage while maintaining adequate access for sensor deployment.
Solution Approach 2:
The patent extracts only the minimal necessary opening area required for sensor deployment. By removing the need for large lance insertion openings and using small sealed openings for drop-in sensors, the vessel structure is minimized in exposure to harmful thermal and mechanical conditions while maintaining probe access capability.
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 reliable, reproducible, and frequent parameter determination with reduced equipment and human intervention, minimizing contamination and energy consumption while enhancing safety and process efficiency.
Implementation Method 1
accelerating the sensor unit with the acceleration means to a speed of at least 5 m/s
Implementation Method 2
measuring the at least one parameter of the high temperature liquid
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 with an acceleration path shorter than 1,4 m, which accelerates the sensor unit to a speed of at least 5 m/s 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.