Metallurgical Furnace Cooling Plate Form-Fit Pipe Joint
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Solution Overview
Problem
The connection between copper pipes and copper stave bodies in metallurgical furnaces is prone to deformation due to wear and thermal stress, leading to weld failures and leakage, as compensators can only absorb a limited degree of deformation before causing stress on the weld, resulting in cracks.
Innovation Solution
A cooling plate design with a receiving bore in the cooling plate body that form-fits with the connection pipe, preventing movement perpendicular to the bore direction, supplemented by a press-fit and welding connection to maintain stability and integrity, reducing stress on the weld.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a weld connection is used between the connection pipe and cooling plate body, then the connection provides structural integrity, but the weld seam becomes a weak point that cracks under thermal stress and deformation
Solution Approach 1:
The connection structure is segmented into three functional zones: a form-fit section for mechanical interlocking, a transition section for stress distribution, and a weld section for sealing. This segmentation allows each zone to perform its specific function optimally without the weld bearing the full mechanical stress
Solution Approach 2:
The form-fit connection and transition section are designed beforehand to absorb and distribute thermal stresses and deformations before they reach the weld seam. This pre-cushioning effect protects the weld from cracking by preventing stress concentration at the weld zone
2Reliability
If a compensator is welded to absorb deformation, then gas-tightness is improved, but the compensator becomes a fix point that transfers load to the weld during excessive deformation
Solution Approach 1:
The solution moves from a single-point compensator approach to a distributed form-fit connection along the connection pipe. The form-fit engagement occurs along the entire inserted length, distributing the deformation absorption across multiple contact points rather than a single fix point, thereby reducing peak loads on the weld
3Manufacturing precision
If the connection pipe is rigidly fixed to maintain position, then alignment is improved, but the connection cannot accommodate thermal expansion and deformation
Solution Approach 1:
The connection structure transitions from a static rigid fix to a dynamic system that adapts to thermal conditions. The form-fit connection maintains positional stability while the transition section and weld geometry allow controlled movement and deformation accommodation, enabling the connection to adapt to thermal expansion and stress conditions during operation
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
The design ensures a secure and leak-resistant connection between the connection pipe and cooling plate body, even under deformation, reducing production costs and maintaining coolant flow efficiency.
Implementation Method 1
an end portion of the connection pipe is press-fitted into a receiving bore in the cooling plate body, form-fittingly preventing movement perpendicular to the bore direction
Implementation Method 2
supplemented by a press-fit and welding connection to maintain stability and integrity
Data Source
AI summary
A metallurgical furnace cooling plate includes a cooling plate body with front and rear faces and at least one coolant channel inside the body, which communicates with a rear opening on the rear face; and a connection pipe connected to the body so that a pipe channel of the connection pipe communicates with the coolant channel, the connection pipe adapted for carrying coolant fluid to or from the channel.The body includes a receiving bore extending in a bore direction from the rear opening into the coolant channel, the channel being spaced in the bore direction from the rear face by a cover thickness of a cover portion and extends in the bore direction over a width. A connection pipe end portion extends into the receiving bore beyond the cover thickness and is form-fittingly received in the receiving bore along at least a portion of a width of the channel.