Ultrasonic Cooling Plate Thickness Measurement via Expandable Probe
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Solution Overview
Problem
Current thickness measurement systems for cooling plates in blast furnaces are insufficient as they only allow local measurements, leading to incorrect assessments of wear and residual life, as they fail to accurately measure the thickness along the entire length of the cooling plate, particularly in the middle section where wear is more pronounced.
Innovation Solution
A device with an ultrasonic probe holder and expandable structure is designed to fit inside the coolant channel, allowing for measurements along the entire length by deploying an expandable structure that expands to occupy the full diameter of the channel, ensuring continuous contact and accurate thickness measurement from the front side to the coolant channel surface, assisted by a flexible cord for progression control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If ultrasonic probe is mounted at the end of a flexible extension member to measure thickness locally, then the measurement system is simple and easy to operate, but the measurement coverage is limited and cannot assess wear along the entire cooling plate length
Solution Approach 1:
The cooling plate measurement task is segmented into multiple measurement points along its length. The expandable structure divides the measurement process into discrete locations (inlet, middle, outlet regions) that can be systematically assessed by deploying the probe to different positions within the coolant channel.
Solution Approach 2:
The measurement approach transitions from a single-point local measurement to a multi-dimensional assessment along the length of the cooling plate. By enabling measurements at multiple locations (inlet, middle, outlet) and using the expandable structure to access different radial positions within the coolant channel, the system captures wear information across the entire plate length.
2Measurement precision
If ultrasonic sensor unit is installed at each measuring point with contact legs or balloon to ensure close contact, then measurement precision is improved, but device complexity increases significantly
Solution Approach 1:
A single universal probe holder design with an expandable structure serves multiple measurement functions. The same device can measure thickness at inlet, middle, and outlet regions of the cooling plate by simply repositioning it along the coolant channel, eliminating the need for different specialized sensors at each location.
Solution Approach 2:
The probe holder incorporates a dynamic expandable structure that can transition between compact and expanded states. This dynamic mechanism allows the probe to adapt its configuration based on the measurement requirements, expanding to ensure close contact with the cooling plate surface for accurate measurements while maintaining operational simplicity.
3Loss of information
If expandable structure is deployed to occupy full diameter of coolant channel, then measurement coverage and contact assurance are improved, but device complexity and insertion difficulty increase
Solution Approach 1:
The probe holder employs a nested configuration where the expandable structure is contained within the probe holder housing in a compact state for easy insertion. Once positioned at the desired measurement location, the expandable structure deploys outward to contact the coolant channel walls, ensuring comprehensive measurement coverage while maintaining a simple insertion profile.
Solution Approach 2:
The probe holder is inserted into the coolant channel in a compact, retracted state before deployment. This preliminary insertion phase simplifies the process by allowing the device to reach its measurement position without the complexity of the expanded structure. Only after proper positioning is achieved does the expandable structure deploy to ensure accurate contact measurements.
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 solution provides a reliable and comprehensive assessment of cooling plate wear by enabling measurements at multiple locations along the coolant channel, including the central regions, thereby improving the accuracy of wear analysis and residual life forecasting.
Implementation Method 1
an ultrasonic probe being arranged in the probe holder housing to be able to transmit and receive ultrasonic waves from the front sensor side
Implementation Method 2
The expandable structure is configured to expand from a compact configuration to an expanded configuration, which is designed to bear against the inner surface of the coolant channel and bias the sensor side of the sensor housing against the inner surface of the coolant channel
Data Source
Figure 1~2
Figure 3~4
AI summary
A device (10) and method for measuring the thickness of a cooling plate (12) are disclosed. The device is designed to fit inside a coolant channel (16) of the cooling plate and comprises a probe holder housing (26) having a front sensor side (30) and an opposite back side (32), in which an ultrasonic probe (28) is arranged. A flexible cord (60) is linked to the probe housing to assist the progression of the probe holder through the length of the coolant channel. The probe holder includes an expandable structure (41) comprising a front and a rear lever (44, 46) articulated on the housing (26) at opposite ends wherein spring means (63) are arranged to bias the levers (44, 46) towards one another. The expandable structure is configured to expand from a compact configuration to an expanded configuration, designed to bear against the inner surface (42) of said coolant channel (16) and bias the sensor side (30) of the sensor housing against the inner surface (42) of the coolant channel.