Flow Rate Detecting Rod Deflection Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for measuring the flow rate of high-temperature steel melt near its surface in a crystallizer are complex and prone to large errors due to the harsh environment, leading to inaccuracies in controlling the flow field and surface quality of continuous casting blanks.
Innovation Solution
A device comprising a flow rate detecting rod with a deflection means, including a counterweight, deflection bearing sleeve, and angle indicating board, which calculates the flow rate by measuring the deflection angle and insertion depth of the rod within the steel melt, using formulas to determine the impact force and drag coefficient, thereby improving measurement precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pressure sensor and ceramic rod are used to measure flow rate by impact pressure, then flow rate measurement is enabled in high-temperature steel melt, but the device becomes complicated and measurement precision deteriorates due to harsh environment influence
Solution Approach 1:
The patent extracts the flow rate detection function from complex pressure sensing systems and implements it through a simple rod that directly measures deflection angle caused by steel melt impact. The rod's deflection angle, measured by a non-contact optical system, directly correlates to flow rate, eliminating the need for complex pressure sensors and ceramic rods while improving precision in high-temperature environments.
Solution Approach 2:
The patent replaces the mechanical pressure sensor system with an optical measurement system. Instead of using pressure sensors that suffer from temperature influence and mechanical complexity, the system uses a rod whose deflection angle is measured optically, substituting mechanical sensing with optical detection to eliminate temperature-related errors and simplify the device.
2Measurement precision
If the pivot of the pressure sensing rod is located adjacent to the upper top, then the rod can be supported, but a large moment is needed to rotate the rod, reducing sensitivity of flow rate measurement
Solution Approach 1:
Instead of positioning the pivot at the top of the rod and measuring rotation from there, the patent inverts the approach by positioning the pivot at the bottom insertion point and measuring the deflection angle of the rod's upper portion. This inversion reduces the moment arm and the force required to achieve measurable deflection, thereby increasing sensitivity.
Solution Approach 2:
The patent changes the measurement dimension from top-down rotation measurement to side-view deflection angle measurement. By measuring the angle between the rod and the vertical direction rather than rotation around a top pivot, the system reduces the required moment and increases sensitivity to flow rate changes.
3Manufacturing precision
If upward countercurrent flow rate is increased to improve flow field control, then surface quality improves, but mold flux engulfment increases leading to surface flaws
Solution Approach 1:
The patent implements a feedback control system where the measured flow rate from the detecting rod is used to adjust the upward countercurrent flow rate. By continuously monitoring and adjusting the flow rate, the system maintains optimal conditions that prevent both surface flaws from insufficient flow and mold flux engulfment from excessive flow, thereby improving surface quality without causing harmful engulfment.
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 solution provides high precision, reliable, and cost-effective measurement of the flow rate, reducing surface flaws in continuous casting blanks and improving the quality of cold rolled products like automobile shell plates by accurately controlling the flow field.
Implementation Method 1
a ceramic rod is inserted into steel melt and applies a pressure to a pressure sensor arranged above the ceramic rod along the flow direction due to the impact of the flowing movement of the steel melt
Implementation Method 2
the drag force coefficient, thereby calculating the flow rate of the steel melt
Implementation Method 3
Both the deflection bearing sleeve and the deflection bearing are circular parts, and the deflection bearing is slidably set against the inner wall of the deflection bearing sleeve
Implementation Method 4
The outer surface of the deflection bearing sleeve comprises a counterweight rod extending outward. The counterweight rod and the flow rate detecting rod fastening screw are fixed to the outer surface of the deflection bearing sleeve, and they are spaced by 180 degrees. The flow rate detecting rod counterweight is fixed to the counterweight rod.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention discloses a device and a method for measuring the flow rate of steel melt near the surface thereof, wherein the device comprises a flow rate detecting rod (18) and a deflection means (B) for the flow rate detecting rod. The deflection device (B) for the flow rate detecting rod comprises a flow rate detecting rod counterweight (20), a deflection bearing sleeve (23), a deflection bearing (24), a deflection angle indicating board (25), a deflection angle pointer (26) and a the flow rate detecting rod fastening bolt (27). Both the deflection bearing sleeve (23) and the deflection bearing (24) are circular parts, and the deflection bearing (24) is slidably set against the inner wall of the deflection bearing sleeve (23). The outer surface of the deflection bearing sleeve (23) comprises a counterweight rod extending outward. The counterweight rod and the flow rate detecting rod fastening bolt (27) are respectively fixed to the outer surface of the deflection bearing sleeve (23). The flow rate detecting rod counterweight (20) is fixed on the counterweight rod. The method comprises the following steps of calculating the distance between the rotational pivot and the barycenter, as well as the distance between the rotational pivot and the acting point of the impact force based on the barycenter, a rotational pivot and an acting point of an impact force of a flow rate detecting rod (18); measuring the gravity value of the flow rate detecting rod (18); inserting the flow rate detecting rod (18) into the steel melt to measure the rotational angle and insertion depth; and thereby calculating the flow rate of the steel melt.