Furnace Load Measurement via Segmented Roller Weighing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for controlling the continuous feeding of scrap metal into electric arc furnaces lack precision, leading to inefficiencies such as prolonged smelting times, electrode rupture risks, and human error, due to unreliable weight measurement techniques that are affected by erosive phenomena and mechanical stress.
Innovation Solution
An automatic system that weighs the furnace shell and its contents using dual-redundant sensors on support rollers, optimizing load flow by adjusting feeding speed based on energy supplied, with a configuration that minimizes mechanical stress and enhances measurement precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct weight measurement systems are installed in support uprights and beams, then weight measurement capability is provided, but measurement precision deteriorates because the measured weight includes only a limited percentage fraction of the load material due to support structure weight
Solution Approach 1:
The weighing function is segmented from the support structure by placing rollers specifically for weighing purposes, separate from the structural support elements. This allows the weighing system to measure only the load material weight without being contaminated by the weight of support uprights and beams.
Solution Approach 2:
Rollers are introduced as intermediary elements between the load material and the weighing system. These rollers carry the load material and transfer its weight to the measurement device, acting as a mediator that isolates the measurement from the complex support structure weight.
2Measurement precision
If wheel mounted tilting furnaces use weighing systems on the wheels, then the furnace can be tilted for operation, but measurement precision deteriorates because the weighing system must resist strong mechanical stress
Solution Approach 1:
The weighing function is separated from the tilting mechanism by using rollers that are not part of the wheel assembly. The rollers are positioned to support the load material independently from the tilting wheels, allowing precise measurement without being subjected to the mechanical stresses of tilting operations.
Solution Approach 2:
The roller support system is designed to cushion and absorb the mechanical stresses that would otherwise affect the weighing accuracy. By positioning the rollers to bear the load independently from the tilting mechanism, the system pre-compensates for stress-induced measurement errors.
3Measurement precision
If indirect control method based on liquid level reading is used, then furnace shell weight can be monitored, but measurement precision deteriorates due to erosive phenomena and lack of precision in taring curve
Solution Approach 1:
The indirect liquid level-based measurement system is replaced with a direct mechanical weighing system using rollers. Instead of inferring weight from liquid level readings that are affected by erosion and refractory profile changes, the system directly measures the weight of the load material through the roller support mechanism, eliminating the harmful effects of erosion on measurement accuracy.
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 ensures precise control of the scrap metal feeding, maintaining optimal temperature and energy efficiency, reducing human error, and supporting real-time decision-making, while providing a reliable and cost-effective monitoring system.
Implementation Method 1
a device to weigh the furnace shell, its contents and any other components it may support
Data Source
AI summary
A system and equipment to measure and control the feeding of load material into an electrical arc furnace (EAF) includes an automatic control device feeding the load material; a measuring device positioned between the EAF and the tilting platform that includes an upper plate adapted to slide against the EAF, a lower plate engaged to the tilting platform, and a ring structure therebetween having a peripheral ring wall, a ring plate extending across the ring structure, and a contact member coupled to the ring plate that upperly contacts the upper plate and lowerly approaches, without contacting the lower plate; and one or more sensors measuring a deformation of the ring plate upon application of a load on the upper plate.