Infrared Sensor Sheath for Molten Metal Temperature Measurement

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Solution Overview

Problem

Conventional temperature measurement techniques for molten metal in metal casting involve disposable platinum-based thermocouples, leading to significant waste and cost due to the need for frequent replacements.

Innovation Solution

A non-contact temperature measurement device using an infrared sensor with an alumina-graphite sheath and an infrared-transparent window or rod that allows for reusable components, preventing molten metal leakage and reducing waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional platinum-based thermocouples are used for temperature measurement, then temperature reading accuracy is maintained, but component replacement frequency increases leading to higher costs and waste

Engineering Contradiction:

Improvetemperature reading accuracyVSAvoidplatinum waste

Core Design Contradiction:

Measurement precisionVSLoss of substance

Solution Approach 1:

The patent replaces the contact-based thermocouple measurement system with a non-contact infrared temperature measurement system. The infrared sensor detects thermal radiation from the molten metal through the transparent window, eliminating the need for physical contact and preventing contamination that would require frequent replacement of the measurement component.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an infrared-transparent window as an intermediary medium between the infrared sensor and the molten metal. This window allows infrared radiation to pass through while protecting the sensor from direct exposure to the molten metal, enabling sustained operation without frequent replacement.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If disposable thermocouples are used, then measurement reliability is ensured, but device complexity and disposal requirements increase

Engineering Contradiction:

Improvemeasurement reliabilityVSAvoiddisposal system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the disposable thermocouple system with a reusable infrared measurement system. The non-contact measurement approach combined with the protective window allows the sensor to remain outside the molten metal environment, eliminating disposal requirements and reducing system complexity related to waste management.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of information

If contact-based measurement is used, then temperature data is obtained, but molten metal leakage risk increases

Engineering Contradiction:

Improvetemperature data acquisitionVSAvoidmolten metal leakage

Core Design Contradiction:

Loss of informationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces contact-based temperature measurement with non-contact infrared measurement. The infrared sensor detects temperature through thermal radiation without physical contact with the molten metal, eliminating the pathway for metal leakage and improving safety.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The infrared-transparent window serves as an intermediary barrier that allows infrared radiation to pass through while preventing direct contact between the sensor and molten metal. This intermediary structure eliminates the leakage risk associated with contact-based measurement systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The solution enables cost-effective and sustainable temperature measurement by allowing the reuse of components, reducing waste and maintaining accuracy in molten metal temperature monitoring.

Implementation Method 1

an infrared sensor effective to measure the temperature of the molten metal

Methodology Applied

Scientific EffectInfrared radiation detection: Infrared Radiation

Implementation Method 2

an infrared-transparent window disposed between the infrared sensor and the channel of the sheath

Methodology Applied

Scientific EffectInfrared transmission: Infrared Radiation

Data Source

PatentUS9671291B2Non-contact temperature measurement in molten metal applications

Publication Date: 2017.06.06 CCPI INC

AI summary

A device to measure a temperature of molten metal may include an infrared sensor effective to measure the temperature of the molten metal, a sheath having an open end, a sealed end, and a channel extending from the open end to the sealed end, and an infrared-transparent window disposed between the infrared sensor and the channel of the sheath. The open end of the sheath is disposed near the infrared sensor and the sealed end of the sheath extends into the molten metal. The infrared-transparent window or rod is disposed between the infrared sensor and the channel of the sheath such that the infrared sensor can measure the temperature through the infrared-transparent window or rod, the channel, and the sealed end. The infrared-transparent window or rod seals the infrared sensor from the channel in the sheath.