Automated Contact Rod Insertion in Metallurgical Probes
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Solution Overview
Problem
Automated insertion of a contact rod into a metallurgical probe is challenging due to plastic deformation and vibrations, requiring precise positioning, which is difficult to achieve without complex and expensive centering devices in harsh operating conditions.
Innovation Solution
A method using a holding and movement apparatus with a bearing point and contact rod centering device that allows for reliable insertion of the contact rod into the probe without the need for complex actuated systems, utilizing probe centering elements and a contact rod centering device to stabilize and position the contact rod, and allowing for partial insertion followed by full insertion to accommodate deformation and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a complex actuated centering device with moving parts is used to enable automated insertion, then automated insertion becomes possible, but device complexity and cost increase significantly
Solution Approach 1:
The system uses the robot's own movement and the elastic deformation of the contact rod to achieve centering and insertion automatically, without requiring a separate actuated centering device. The contact rod's elasticity allows it to bend during insertion and return to its original position, enabling self-centering.
Solution Approach 2:
The system changes the physical state of the contact rod from rigid to elastically deformable during insertion. By allowing temporary elastic deformation and subsequent recovery, the system achieves precise positioning and centering without complex mechanical devices.
2Manufacturing precision
If precise positioning is required for contact rod insertion, then insertion accuracy improves, but the system becomes more sensitive to vibrations and deformations
Solution Approach 1:
The system compensates for potential positioning errors and vibrations by allowing elastic deformation of the contact rod during insertion. The elasticity acts as a cushion that absorbs shocks and vibrations, ensuring reliable insertion even under harsh operating conditions.
Solution Approach 2:
The system transitions from a static rigid insertion process to a dynamic process where the contact rod can elastically deform and recover. This dynamic approach allows the system to adapt to vibrations and movements, maintaining insertion accuracy despite external disturbances.
3Ease of operation
If manual attachment is used, then operation flexibility is maintained, but labor intensity increases and automated operation becomes difficult
Solution Approach 1:
The system replaces manual mechanical attachment operations with an automated robotic system. The robot holds the contact rod and performs insertion automatically, eliminating manual labor while maintaining operational flexibility through programmable control.
Data Source
AI summary
A metallurgical probe has a probe longitudinal axis and an open end face. The probe is fitted within a bearing point in such a manner that the open end face faces a predetermined insertion direction. The bearing point has probe centering elements to hold the probe in a predetermined probe position as seen transversely with respect to the probe longitudinal axis. A device inserts an end of the contact rod into a contact rod centering device, in an insertion direction running transversely with respect to the probe longitudinal axis, until the end of the contact rod is positioned, on account of the insertion into the contact rod centering device, in a predetermined contact rod position, in which the end of the contact rod is opposite the open end face. The contact rod is then moved in a direction of the probe longitudinal axis and is inserted into the probe.