High-Temperature Liquid Sensor Acceleration for Controlled Immersion
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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 through existing entry points, minimizing exposure time and reducing the need for additional equipment and human intervention.
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 measurement can be performed, but the operation requires manual intervention and causes safety risks and operational interruptions
Solution Approach 1:
The system uses automatic control means to operate the lance assembly and processing device without manual intervention. The control means automatically controls the immersion depth, immersion speed, and probe retrieval based on pre-set parameters, making the system self-operating and eliminating the need for manual lance assembly operations.
2Ease of operation
If the probe is immersed slowly into the melt, then the operation is safer and easier to control, but the probe burns prematurely and measurements become false
Solution Approach 1:
The system dynamically adjusts the immersion speed of the probe based on real-time conditions and pre-set parameters. The automatic control means ensures the probe is immersed at the optimal speed - fast enough to prevent premature burning but controlled enough to ensure accurate positioning at the required depth for reliable measurements.
3Productivity
If the probe is not immersed deep enough, then the operation is simpler and faster, but the temperature reading is unstable and sensor readings become unreliable
Solution Approach 1:
The system uses feedback control where the processing device continuously monitors the probe position and immersion depth. Based on pre-set target depths and real-time sensor feedback, the automatic control means adjusts the lance assembly to ensure the probe reaches the exact required immersion depth, guaranteeing stable temperature readings and reliable sensor data while maintaining operational efficiency.
4Reliability
If a disposable probe is used after every measurement, then contamination is reduced, but additional components and process steps are required which lengthen the time interval between measurements
Solution Approach 1:
The system automatically retrieves the disposable probe from the molten metal using the lance assembly after measurement. The processing device controls the retrieval process, and the probe is automatically removed and replaced in preparation for the next measurement. This automated discard and replace process minimizes the time interval between measurements while ensuring each disposable probe is used only once for reliable measurements.
5Ease of operation
If the vessel opening is opened for lance insertion, then the probe can be introduced, but the process yield decreases and energy is wasted due to cold air intake
Solution Approach 1:
The system prepares the lance assembly and probe outside the vessel before operation. The automatic control means is pre-programmed with the required immersion depth and speed parameters. When measurement is needed, the pre-prepared lance is quickly inserted through the opening, performs the measurement, and is retrieved. This preliminary preparation minimizes the duration of the vessel opening, reducing cold air intake and maintaining process yield.
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 approach provides reliable, reproducible measurements with reduced material contamination and operational costs, enabling continuous monitoring without disrupting the metallurgical process.
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
Figure 1~2
Figure 3~3B
Figure 4~4B
AI summary
The present invention relates to 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.