Induction-Heated Lance Cartridge for Safe Automatic Ignition
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Solution Overview
Problem
Existing systems for igniting thermal lances are either manually operated, pose safety risks due to liquid steel splashes, require external non-automatable devices, and have reliability issues with pyrotechnic materials that can be hazardous for transport and storage, or depend on specific operating conditions.
Innovation Solution
A device comprising a steel cartridge filled with high calorific value material, such as carbon, and an induction heater assembly that heats the cartridge to a high temperature without oxygen, allowing safe handling and remote ignition of the thermal lance by oxygen flow when positioned correctly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external ignition devices (welding torch) are used, then ignition can be achieved, but manual operation and safety risks from liquid steel splashes increase
Solution Approach 1:
The patent replaces manual mechanical ignition operations with an automated induction heating system. The induction heater assembly uses electromagnetic induction to heat the cartridge automatically, eliminating the need for manual welding torch operation and reducing exposure to liquid steel splashes while maintaining reliable ignition.
Solution Approach 2:
The patent introduces a cartridge as an intermediary component between the induction heater and the thermal lance. The cartridge contains high calorific value material that is heated by induction and then transfers the ignition energy to the thermal lance, serving as a safe mediator that isolates the operator from direct exposure to molten steel and ignition hazards.
2Extent of automation
If pyrotechnic materials (iron thermite) are used for self-ignition, then automatic ignition is achieved, but transport and storage safety risks increase due to explosion hazards
Solution Approach 1:
The patent changes the chemical composition parameters of the ignition material from pyrotechnic mixtures (iron thermite) to high calorific value materials (carbon, coal, oil). This parameter change eliminates the spontaneous ignition and explosion hazards associated with pyrotechnics while maintaining the ability to achieve automatic ignition through controlled induction heating.
Solution Approach 2:
The patent creates a safer, more stable environment by using carbon-based materials instead of pyrotechnic compositions. These materials do not spontaneously ignite and are not explosive under normal handling, transport, and storage conditions, effectively creating an inert-like safety profile while still enabling automatic ignition through external heating.
3Extent of automation
If incorporated electric arc ignition is used, then automatic ignition is achieved, but device complexity and cost increase
Solution Approach 1:
The patent divides the ignition system into separate components: an external induction heater assembly and a simple cartridge that attaches to the thermal lance. This segmentation allows the complex induction heating mechanism to be separated from the lance itself, keeping the lance design simple while achieving automatic ignition through the external device.
Solution Approach 2:
The cartridge serves as a simple intermediary component that requires no complex internal ignition mechanisms. It merely holds the high calorific value material and interfaces with both the induction heater and the thermal lance, significantly reducing the complexity of the overall system compared to incorporating electric arc ignition directly into the lance.
4Reliability
If manual ignition by two operators is used, then ignition can be achieved, but productivity decreases and safety risks increase
Solution Approach 1:
The system enables self-service automatic ignition where the induction heater assembly autonomously heats the cartridge and triggers the thermal lance ignition without requiring multiple operators. The process is self-contained and automated, improving both safety by reducing human exposure and productivity by eliminating coordination requirements between operators.
Solution Approach 2:
The patent replaces the manual mechanical operation of two operators with an automated induction heating system. The electromagnetic induction process automatically heats the cartridge to ignition temperature and triggers the thermal lance, eliminating the need for human intervention and significantly improving both safety and operational efficiency.
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
Enables automatic, safe, and reliable ignition of thermal lances without spontaneous ignition or explosion risks, reducing human intervention and improving handling safety, with lower costs and no need for external ignition methods like pressure or friction.
Implementation Method 1
an induction heater assembly (16), adapted to heat the cartridge (10)
Implementation Method 2
an induction heater assembly (16), adapted to heat the cartridge (10)
Implementation Method 3
a cartridge (10) which is adapted to be supplied by oxygen (17) for igniting
Implementation Method 4
an exothermic reaction, which brings the cutting end of the lance to a temperature ranging from 3500° C. to above 5000° C.
Data Source
AI summary
A device for igniting oxygen thermal lances or melting lances may include: a cartridge configured to couple to an operating end of a thermal or melting lance, configured to be supplied with oxygen to ignite the lance, and containing high calorific value material; and an induction heater assembly configured to heat the cartridge, such that the high calorific value material is burnt before supplying the oxygen into the cartridge to ignite the lance. The cartridge may include: a first end configured to couple to an operating end of a lance; and a second end having one or more axial holes for passing oxygen into the cartridge. An assembly for igniting oxygen thermal lances or melting lances may include: the device; the lance coupled to an end of the cartridge; a robotic arm configured to handle the lance; and a supply of oxygen in fluid communication with the lance and cartridge.