Gas Purging Plug Vibration Sensor Steel Melt Control
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Solution Overview
Problem
Existing gas purging plugs for metal melts lack reliable methods to control and reproduce gas bubble distributions, leading to inconsistent steel quality due to wear and production variances, affecting the removal of non-metallic impurities and steel cleanliness.
Innovation Solution
A gas purging plug system equipped with an electronic sensor to measure structure-borne vibrations from gas bubbles, allowing for real-time analysis of gas bubble distribution and adjustment of gas flow to maintain consistent bubble sizes and quantities, using a data processing unit and control unit to calculate a bubble index signal and adjust the volume flow accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gas flow rate is increased to improve impurity removal efficiency, then steel cleanliness improves, but gas bubble distribution becomes inconsistent leading to quality variability
Solution Approach 1:
The patent implements a feedback control system where vibration sensors monitor the gas purging plug's oscillation characteristics in real-time. The control unit processes these vibration signals to determine gas bubble distribution parameters, and automatically adjusts the gas flow rate to maintain consistent bubble distribution. This closed-loop feedback mechanism ensures reliable steel cleanliness while preventing quality variability.
Solution Approach 2:
The patent replaces direct mechanical measurement of gas bubble distribution with indirect vibration-based measurement. Instead of mechanically measuring bubble size and distribution, the system uses vibration sensors to detect oscillations caused by gas bubbles, converting a difficult mechanical measurement into an easier vibrational signal analysis that enables precise control.
2Manufacturing precision
If vibration-based measurement is implemented to control gas bubble distribution, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The gas purging plug serves multiple functions: it introduces gas into the steel melt, generates characteristic vibrations based on bubble distribution, and acts as the mounting structure for vibration sensors. This multi-functionality reduces overall system complexity by combining measurement and processing functions into the existing plug structure rather than adding separate complex measurement systems.
Solution Approach 2:
The patent uses vibration signals as an intermediary to indirectly measure gas bubble distribution. Instead of directly measuring difficult-to-access bubble parameters, the system measures vibrations that mediate between gas flow and bubble characteristics, simplifying the measurement process while maintaining precision.
3Reliability
If real-time vibration monitoring is used to maintain consistent bubble distribution, then production reliability improves, but energy consumption increases
Solution Approach 1:
The system monitors vibration signals continuously but only activates active gas flow adjustment when vibration parameters indicate deviations from optimal bubble distribution. During normal operation, the system relies on passive vibration monitoring without continuous active correction, reducing energy consumption while maintaining production reliability through selective intervention.
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 system ensures consistent gas bubble distribution, improving steel purity and production reliability by dynamically controlling gas flow based on real-time bubble index signals, reducing impurity removal variability and maintaining consistent steel quality.
Implementation Method 1
at least one electronic sensor in contact with the gas purging plug, to detect an oscillation of a mechanical vibration
Data Source
AI summary
Various embodiments provide for a gas purging plug (10) with a ceramic refractory body (10k) with a first end (10u) and a second end (10o); the second end (10o) is in the mounted position of the gas purging plug (10) in contact with a metal melt (41); the first end (10u) is at least partially covered with a metal cover (12.1), the metal cover (12.1) comprises an opening (16) to which optionally a gas supply adapter (20) is connected; the gas purging plug (10) is designed in such a way, that a purging gas which is supplied via the gas supply pipe (30) to the opening (16) flows through the body (10k) and exits the body (10k) at the second end (10o); and wherein at least one electronic sensor (70, 70.1, 70.2, 70.3, 70.4) is in contact with the gas purging plug (10), to detect a mechanical vibration (81).