Cooled Infrared Sensor in Ceramic Tube for Tundish Steel
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Solution Overview
Problem
Current methods for continuous temperature measurement of molten steel face challenges such as high temperature exposure risks for operators, complex sensor protection and installation, and interference from changing steel bath levels, which affect measurement accuracy and reliability.
Innovation Solution
A device featuring a cooled jacket for a two-color optical infra-red sensor with an optical fiber and signal converter, housed within a ceramic tube made of pressed graphited alumina, which allows for precise temperature measurement and easy maintenance, with a temperature controller for safety and a design that minimizes operator exposure and interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical infra-red sensor is used for temperature measurement, then measurement precision is improved, but sensor protection and installation complexity increases
Solution Approach 1:
A ceramic tube is introduced as an intermediary component between the optical sensor and the molten steel. The tube protects the sensor from direct exposure to molten steel while allowing infrared radiation to pass through, thus maintaining measurement precision while reducing installation and protection complexity
Solution Approach 2:
The measurement system is divided into separate functional components: the optical sensor, the ceramic protection tube, and the cooling system. This segmentation allows each component to be optimized independently and simplifies installation and maintenance
2Reliability
If sensor is exposed to high temperature environment, then measurement capability is improved, but operator safety deteriorates
Solution Approach 1:
The ceramic tube acts as a thermal barrier and intermediary structure that allows the sensor to measure high temperature molten steel while keeping the sensor body and operator in a safe temperature zone
Solution Approach 2:
The system replaces direct mechanical contact measurement methods with optical measurement through the ceramic tube, eliminating the need for physical sensor insertion into the molten steel and thereby protecting operators from high temperature exposure
3Reliability
If ceramic tube is designed for sensor protection, then sensor reliability is improved, but maintenance difficulty increases
Solution Approach 1:
The ceramic tube is designed as a separate, replaceable component that can be easily removed and replaced without affecting the sensor itself, thus maintaining sensor reliability while simplifying maintenance operations
Solution Approach 2:
The ceramic tube is designed as a consumable protection element that can be easily replaced when worn or damaged, rather than attempting to repair it, reducing maintenance complexity and downtime
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
Enhances operating safety, reduces maintenance costs, and improves measurement reliability by protecting the sensor and reducing operator exposure to high temperatures, while allowing for precise temperature control and easy ceramic tube replacement.
Implementation Method 1
The optical unit, which is the very measuring unit, comprises one optical sensor... The optical fiber carries the signal from the optical sensor up to the signal conversion device... The readings are processed by the electronic signal converter by means of a mathematical equation that calculates and displays the temperature
Implementation Method 2
The optical fiber carries the signal from the optical sensor up to the signal conversion device
Implementation Method 3
ideal sensor and optical fiber cooling without affecting the measurement... A device was designed to allow the adaptation of and protection to both the measuring tube and the optical instrument
Data Source
AI summary
The system developed for the continuos temperature measurement of molten metal (1), like in the case of the continuous casting machine tundish (2), uses an optical process to control the continuous casting machine speed, and it consists of an optical infra-red sensor (8) protected by a cooled jacket (30). This two-color sensor (8), fitted with optical fiber (9) and an optical signal converter (10), is focused inside a high thermal and light conductivity ceramic tube (15), and it enables accurate temperature readings of molten steel (1) in the tundish (2).This practical device avoids the inconvenience of the method currently being used. It reduces the operator's high temperature exposure time, lowers maintenance downtime, minimizes the operating risks, improves safety and enables fast, simple replacement, resulting in improved slab quality and, as a consequence, lower costs.