Light-Projected Anchor Layout for Refractory Vessel Installation
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Solution Overview
Problem
The process of identifying installation locations for refractory anchors in thermal-process vessels is time-consuming and requires skilled labor, contributing to significant downtime and costs due to the need for periodic refractory lining replacements.
Innovation Solution
A light-projecting system that uses a light module with a light emitter and diffractor to project multiple light beams onto an installation surface, forming a pattern of light indicia to identify installation locations, which can be adjusted using linear mechanisms and distancing devices to ensure accurate spacing for anchor installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional measuring and chalk-line tools are used to mark anchor locations, then installation locations can be identified, but the process is time-consuming and requires skilled labor
Solution Approach 1:
The patent replaces traditional mechanical measuring and chalk-line tools with a laser-based light-projecting system. The laser module projects light beams that automatically mark anchor locations on the installation surface, eliminating the need for manual measurement and chalk-line marking. This substitution of mechanical systems with optical systems achieves both high precision and time efficiency.
Solution Approach 2:
The light-projecting system is designed to be self-guiding and automated. The laser module automatically projects light beams at predetermined angles and positions to mark anchor locations without requiring skilled craftsmanship for layout patterns, measures, or technical drawings. The system performs the layout task autonomously, reducing dependency on operator expertise and minimizing task duration.
2Manufacturing precision
If skilled craftspersons perform the layout task with advanced technical understanding, then accurate anchor spacing is achieved, but the process remains time-consuming
Solution Approach 1:
The patent replaces the skilled craftsperson's manual layout process with an automated laser-projecting system. The system uses predetermined light beam angles and positions to automatically establish accurate anchor spacing, eliminating the need for operators to possess advanced technical understanding of layout patterns and measures. This automation maintains manufacturing precision while dramatically improving productivity.
Solution Approach 2:
The system establishes accurate anchor spacing by controlling laser beam parameters such as projection angles, beam positions, and light intensity. By adjusting these optical parameters, the system achieves precise anchor location marking without requiring manual measurement and calculation, thereby improving both accuracy and efficiency.
3Strength
If refractory anchors are installed in arrays to secure refractory lining, then mechanical and structural integrity is protected, but significant downtime and costs occur due to periodic replacement
Solution Approach 1:
The light-projecting system enables rapid and accurate layout of anchor locations, allowing for efficient installation of refractory anchors during initial construction or replacement operations. By automating the layout process, the system reduces installation time and facilitates quicker completion of refractory lining jobs, thereby minimizing downtime and associated costs.
4Productivity
If modern welding systems are used to install anchors, then installation speed is improved, but the layout task still takes as long as the anchor installation task itself
Solution Approach 1:
The patent replaces the manual layout process with an automated laser-projecting system that quickly marks anchor locations. This optical system performs the layout task in a fraction of the time required for traditional manual methods, making the layout duration comparable to or shorter than the actual anchor installation time when using modern welding systems. The substitution eliminates the bottleneck in the overall installation process.
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 system significantly reduces the time and skill required for laying out anchor locations, enhancing efficiency and reducing downtime by enabling precise and automated marking of installation sites.
Implementation Method 1
a diffractor (e.g., a diffractive optical element) that diffuses the source light beam into the multiple light beams
Data Source
AI summary
A light module projects multiple light beams onto an installation surface to form multiple light indicia spaced apart in a pattern on the installation surface, with the light indicia identifying installation locations on the installation surface where construction mounts are then installed. The light module includes a light emitter that projects a source light beam and a diffractor that splits the source light beam into the multiple light beams. The light module is adjustably mounted to and movable with a handheld tool used to install the construction mounts. The light module is adjustably mounted to a static-use support.