Light Projection Layout for Precise Refractory Anchor Installation
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Solution Overview
Problem
The process of laying out refractory anchor installation locations in high-temperature vessels is time-consuming and requires skilled labor, contributing to significant downtime and costs in industrial facilities.
Innovation Solution
A light-projecting system that uses a light emitter and diffractor to project multiple light beams onto an installation surface, forming a pattern of indicia to identify anchor installation locations, with adjustable mechanisms for precise spacing and distance control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional measuring and chalk-line tools are used to mark installation locations, then installation precision can be maintained, but the layout process becomes extremely time-consuming and requires skilled labor
Solution Approach 1:
The patent replaces the mechanical chalk-line layout system with an optical projection system. A portable projector displays illuminated patterns (grids, lines, or pre-defined layouts) directly onto the installation surface, eliminating the need for manual measuring and chalk-line marking. This substitution maintains installation precision while dramatically reducing layout time and skill requirements.
Solution Approach 2:
The patent creates a visual copy of the desired anchor layout pattern by projecting illuminated images onto the installation surface. Instead of physically marking locations with chalk lines, the system projects a light-based representation of the entire layout pattern, allowing workers to directly follow the projected guide without complex manual layout procedures.
2Manufacturing precision
If traditional layout methods are used, then installation accuracy can be ensured, but the complexity of the layout process increases due to requiring skilled craftsmen
Solution Approach 1:
The patent replaces the complex human skill-based layout process with a simplified optical projection system. The projector contains pre-programmed layout patterns that are automatically displayed, eliminating the need for workers to understand complex layout techniques. This reduces process complexity while maintaining accuracy through the precision of the projected optical guides.
Solution Approach 2:
The patent changes the fundamental parameter of layout delivery from manual measurement and marking to optical projection. By transforming the layout information into visible light patterns, the system simplifies the workflow while maintaining precision, as the projected patterns provide direct visual guidance without requiring interpretation or complex manual procedures.
3Manufacturing precision
If refractory anchors are installed manually using traditional methods, then installation quality can be maintained, but overall productivity decreases due to time-consuming layout and installation processes
Solution Approach 1:
The patent replaces the sequential manual layout-and-install process with a parallel optical guidance system. The projector displays the complete layout pattern simultaneously, allowing multiple workers to identify and install anchors at different locations at the same time. This parallelization of the installation process significantly increases productivity while maintaining quality through consistent optical guidance.
Solution Approach 2:
The patent performs the layout action in advance by projecting the complete pattern onto the surface before installation begins. This preliminary visualization of all anchor locations allows workers to efficiently plan and execute installations without interruption for repeated measuring and marking, thereby increasing overall installation speed and productivity.
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
Facilitates rapid and accurate placement of refractory anchors, reducing the time and skill required for layout, thereby minimizing facility downtime and costs.
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. Embodiments include systems in which the light module includes a light emitter that projects a source light beam and a diffractor that diffuses the source light beam into the multiple light beams, systems in which the light module is adjustably mounted to and movable with a handheld tool used to install the construction mounts, systems in which the light module is adjustably mounted to a static-use support, and methods of using these systems to install the construction mounts.