LiDAR Refractory Lining Wear Monitoring
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Solution Overview
Problem
Existing methods for monitoring the wear of internal refractory linings in vessels are inefficient, relying on manual visual inspections that are subjective, time-consuming, and lack precision, leading to potential catastrophic failures and high repair costs.
Innovation Solution
A LiDAR-based system that uses a pulsed laser beam to create a mesh of points representing the refractory lining surface, allowing for precise measurement of wear and thickness, even in high-temperature environments, and enabling automated data analysis for decision-making.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection is used to monitor refractory lining wear, then the inspection can be performed with simple equipment, but the measurement precision and reliability are insufficient
Solution Approach 1:
The patent replaces manual visual inspection with a LiDAR-based measurement system that uses laser beams to scan the refractory lining surface. The system projects laser beams onto the lining and detects reflected light to calculate distance measurements, creating a point cloud that represents the surface geometry. This substitution of mechanical/manual inspection with optical measurement enables precise wear detection without requiring complex physical access to the vessel interior.
Solution Approach 2:
The patent creates a digital copy (point cloud) of the refractory lining surface by projecting laser beams and detecting reflected light. This digital representation allows for precise measurement and analysis of wear patterns without requiring physical contact or manual inspection. The point cloud data can be processed to identify wear, cracks, and other defects in the lining.
2Measurement precision
If conventional TOF cameras are used for measurement, then the system can capture surface information, but the number of measurements is limited and wear in between measured points goes undetected
Solution Approach 1:
The patent uses a scanning mechanism that periodically projects laser beams across the refractory lining surface in a systematic pattern. This periodic scanning action ensures complete coverage of the surface, generating numerous measurement points that collectively provide high-resolution mapping of the lining geometry and wear distribution.
3Measurement precision
If predefined spatial coordinate systems are used for measurement heads, then the system can establish reference frames, but any movement results in invalid measurements
Solution Approach 1:
The patent employs a dynamic coordinate system that adapts to the position and orientation of the measurement head during scanning. The system continuously tracks the spatial coordinates of the measurement head and adjusts the reference frame accordingly, allowing valid measurements even when the measurement head moves during operation. This dynamic adaptation eliminates the need for rigid predefined coordinate systems.
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 LiDAR system provides accurate and precise 3D mapping of refractory lining wear, reducing the need for manual inspections, minimizing downtime, and enabling proactive maintenance, thereby preventing costly failures and improving manufacturing efficiency.
Implementation Method 1
a LiDAR device which can be oriented towards the refractory lining through an opening of the vessel and an external structure with respect to the vessel on which the at least one LiDAR device is mounted. The at least one LiDAR device comprises in turn a laser source configured to generate a pulsed laser beam and an optical rotary encoder configured to project the laser beam onto a plurality of points on a surface of the refractory lining through the opening of the vessel and a receiver configured to receive the laser beam reflected at the plurality of points on the surface of the refractory lining
Implementation Method 2
an optical rotary encoder configured to project the laser beam onto a plurality of points on a surface of the refractory lining
Data Source
AI summary
A system for monitoring an internal refractory lining of a vessel adapted to contain molten metal includes at least one LiDAR device orientable towards the refractory lining through an opening of the vessel, an external structure with respect to the vessel on which the at least one LiDAR device is mounted; and wherein the at least one LiDAR device includes: a laser source, an optical rotary encoder; a receiver configured to receive a laser beam reflected at the plurality of points on the surface of the refractory lining; and a controller to calculate a distance between the at least one LiDAR device and each of the plurality of points on the surface of the refractory lining.