High-Temperature Liquid Sensor Projection for Controlled Melt Measurement
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Solution Overview
Problem
Existing methods for determining parameters of high temperature liquids, such as molten metal, are invasive, require manual intervention, and result in unreliable measurements due to uncontrollable immersion and exposure to corrosive environments, leading to increased costs and safety risks.
Innovation Solution
A method using a lightweight sensor unit accelerated by means positioned close to the liquid surface, allowing controlled immersion and minimizing exposure time, which can be introduced through existing openings in metallurgical vessels without a lance, enabling non-invasive and frequent parameter determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a lance assembly is used to manually insert a probe into the molten metal, then the sensor can be positioned close to the melt surface, but the operation requires manual intervention and causes splashing and safety risks
Solution Approach 1:
The system uses automated robotic manipulation instead of manual operation. The robot gripper automatically holds and positions the lance assembly, and the system autonomously controls the probe insertion and retrieval processes, eliminating manual intervention while maintaining measurement precision
Solution Approach 2:
The manual mechanical operation of lance insertion is replaced with an automated robotic mechanical system. The robot arm and gripper provide controlled, repeatable positioning and manipulation of the probe, eliminating human exposure to splashing and high-temperature environments
2Ease of operation
If the probe is inserted slowly into the melt, then safety is improved, but the probe burns prematurely and measurements become false
Solution Approach 1:
The system dynamically adjusts the insertion speed of the probe based on real-time conditions. The robotic system controls the lance to insert the probe at an optimal speed that prevents premature burning while avoiding excessive splashing, achieving both safety and measurement accuracy through adaptive motion control
3Device complexity
If the probe is not immersed deep enough, then the operation is simpler, but the temperature measurement becomes unstable and sensor readings become unreliable
Solution Approach 1:
The system uses feedback control to monitor probe immersion depth and adjust positioning accordingly. Sensors detect when the probe has reached the appropriate depth in the melt, and the robotic system automatically maintains this position, ensuring stable temperature measurements without requiring complex manual judgment about immersion depth
4Measurement precision
If a disposable probe on a lance is used for each measurement, then measurement reliability is improved, but the time interval between measurements increases and productivity decreases
Solution Approach 1:
The system recovers and reuses the lance assembly and sensor components after each measurement. Instead of discarding the entire probe assembly, only the consumable sensor tip is replaced, while the lance and housing are retained for subsequent measurements, significantly reducing preparation time and increasing measurement frequency
5Ease of operation
If the vessel opening is opened for lance insertion, then the probe can be introduced, but energy is wasted from cold air intake and process continuity is interrupted
Solution Approach 1:
The system uses the existing slag door opening for multiple purposes: it serves both as the access point for the robotic lance insertion and as a regular operational component of the furnace. The opening is minimized and optimized to allow probe introduction while maintaining process continuity and reducing energy loss from cold air intake
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 method provides reliable, reproducible, and cost-effective parameter measurement with reduced equipment and human intervention, minimizing contamination and energy consumption while maintaining vessel operation continuity.
Implementation Method 1
providing acceleration means above the surface of the high temperature liquid in a distance DA between the surface of the high temperature liquid and the top opening of the metallurgical container, wherein the acceleration means is adapted to increase the speed of the sensor unit
Data Source
AI summary
A method for determining at least one parameter of a high temperature liquid with a sensor unit and a system to carry out the method. A measuring probe releasably carrying the sensor unit is provided to acceleration means, which accelerates the sensor unit after separation from the measuring probe. The acceleration means is provided in a distance DA to the surface of the high temperature liquid and the distance DA between the surface of the high temperature liquid is less than 50% of the distance of the surface of the high temperature liquid to the opening of the container DM. The sensor unit is projected in the direction of the high temperature liquid, immersed under the surface and the parameter of interest is measured. The invention further relates to a system suitable to carry out the inventive method and a metallurgical vessel comprising the inventive system.