Edge-Mounted Electromagnetic Sensor for Molten Metal Level Measurement
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Solution Overview
Problem
Conventional electromagnetic sensors for measuring molten metal levels in continuous casting molds are hindered by their need to be suspended above the metal, limiting operator access and being sensitive to electromagnetic and thermal disturbances.
Innovation Solution
An electromagnetic sensor with air-oriented coils positioned on the edge of the mold, using a magnetic field parallel to the metal surface, and featuring non-magnetic, air-receiving coils that are less sensitive to disturbances, allowing permanent placement and accurate level measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is suspended above the molten metal to avoid edge effects, then the measurement can be performed, but operator access is hindered and the sensor is sensitive to electromagnetic and thermal disturbances
Solution Approach 1:
The patent changes the orientation of the sensor coils from horizontal (parallel to the metal surface) to vertical (perpendicular to the metal surface). This dimensional change allows the sensor to be positioned on the mold edge rather than suspended above the metal, providing operator access while maintaining measurement capability through the vertical magnetic field configuration
2Measurement precision
If the sensor is suspended above the molten metal, then measurement can be performed, but the sensor is sensitive to electromagnetic and thermal disturbances
Solution Approach 1:
The patent introduces air as an intermediary medium between the sensor coils and the molten metal. The air-oriented coils measure magnetic field variations caused by the metal level without direct contact with the metal, thereby eliminating sensitivity to electromagnetic and thermal disturbances while maintaining measurement accuracy
Solution Approach 2:
By orienting the coils vertically perpendicular to the metal surface, the patent creates a magnetic field configuration that is less susceptible to horizontal electromagnetic and thermal disturbances, while still effectively detecting metal level changes through the vertical field component
3Ease of operation
If the sensor is positioned on the mold edge with coils oriented perpendicular to the metal surface, then operator access is improved and disturbance sensitivity is reduced, but the measurement architecture becomes more complex
Solution Approach 1:
The patent divides the sensor into separate functional components: an excitation coil and two receiving coils (upper and lower). This segmentation allows each coil to have a specific function - the excitation coil generates the magnetic field while the receiving coils detect variations, simplifying the overall architecture and making the sensor easier to position and operate on the mold edge
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 continuous, disturbance-immune measurement of molten metal levels, facilitating operator access and improving measurement accuracy by positioning the sensor on the mold edge with coils oriented perpendicular to the metal surface.
Implementation Method 1
an excitation coil with air oriented perpendicular to the upper face of the mold supplied with a current to create a magnetic field whose field lines propagate along upper field lines which move away from the mold and along lines of lower fields which cover the upper face of the mold and the surface of molten metal
Implementation Method 2
a lower air receiving coil parallel to the excitation coil in which an induced voltage is generated by the action of the lower field lines, the latter being liable to be modified by a variation in the level of the molten metal surface
Implementation Method 3
an upper air receiving coil parallel to the excitation coil, and directly superimposed on the lower receiving coil and of geometry and identical characteristics to this in which an induced voltage is generated by the action of the upper field lines, the latter being substantial nt devoid of disturbances generated by the molten metal surface
Data Source
Figure 1
Figure 2~4
AI summary
The invention relates to a sensor (1) for measuring the surface level of a liquid phase metal in a continuous casting plant including an ingot mold having an upper surface into which an opening (4), in which a liquid metal is fed, leads, characterized in that the sensor includes: an air excitation coil (7) perpendicular to the upper surface of the ingot mold and arranged near the opening, powered by a current for generating a magnetic field, the field lines of which propagate along upper field lines away from the ingot mold and along the lower field lines covering the upper surface of the ingot mold and the molten metal surface; a lower air reception coil (8) parallel to the excitation coil, in which an induced voltage is generated by the action of the lower field lines, wherein the latter can be modified by a variation in the level of the molten metal surface; and an upper air reception coil (9) parallel to the excitation coil, vertically adjacent to the lower excitation coil, and having a shape and characteristics identical to those of the latter, wherein the induced voltage is generated by the action of the upper field lines, the latter being substantially free of disturbances generated by the molten metal surface.