Molten-Metal Measuring Probe Segmentation for Faster Response
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Solution Overview
Problem
Existing measuring probes for molten metal have high material costs, large mass, long response times, and are not suitable for use in electric arc furnaces due to their design, leading to inefficient and costly measurements with significant material contamination and energy waste.
Innovation Solution
A compact measuring probe with individual wires and optimized dimensions, allowing for accelerated immersion and reduced mass, enabling reliable measurements through available entry points without the need for lance systems, and featuring a sensor unit with a thermocouple and electrochemical cell for rapid data acquisition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heavy measuring probe with thick cable is used to withstand molten metal environment, then the cable survival time and measurement reliability are improved, but the probe mass increases significantly and response time increases
Solution Approach 1:
The probe is divided into two separate parts: a lightweight sensor unit that is dropped into the molten metal for measurement, and a heavier carrier tube that remains outside. This segmentation allows the sensor unit to be light and fast-responding while the carrier tube provides structural support and cable protection without adding mass to the measuring portion.
Solution Approach 2:
The cable and its protective housing are extracted from the sensor unit and placed in the carrier tube. Only the essential sensing elements remain in the sensor unit, eliminating unnecessary mass. The cable is routed through the carrier tube rather than being attached to the sensor unit, allowing the sensor to be lightweight while maintaining electrical connection.
2Reliability
If a heavy measuring probe is used to penetrate slag layer and reach molten metal, then measurement reliability is improved, but energy consumption increases and response time increases
Solution Approach 1:
The probe is divided into a lightweight sensor unit and a separate carrier tube. The sensor unit's minimal mass allows it to be rapidly accelerated into the molten metal by gravity alone, minimizing energy consumption. The carrier tube remains stationary and provides structural support without contributing to the energy needed for penetration.
Solution Approach 2:
The sensor unit utilizes its own gravitational potential energy to penetrate the slag layer and reach the molten metal. By minimizing the mass of the sensor unit, the system allows gravity to provide sufficient acceleration without requiring additional energy input mechanisms, making the probe self-sufficient for penetration.
3Reliability
If a thick cable with protective housing is used to protect signal line, then cable survival in molten metal environment is improved, but the carrier tube dimensions and probe mass increase
Solution Approach 1:
The cable and its protective housing are extracted from the sensor unit and placed in the carrier tube. The carrier tube serves as the protective housing for the cable, separating the cable protection function from the sensor unit. This allows the sensor unit to be compact while the carrier tube provides adequate protection for the cable.
Solution Approach 2:
The carrier tube serves multiple functions: it provides structural support for the entire probe assembly, houses and protects the cable during the measurement process, and guides the sensor unit into the molten metal. By consolidating these functions in a single component, the overall system complexity and dimension requirements are reduced.
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 probe achieves faster response times, reduced material contamination, and lower operational costs by minimizing probe mass and energy consumption, while maintaining measurement reliability and versatility across various metallurgical vessels.
Implementation Method 1
A sensor unit comprising at least one sensor, for example a temperature sensor and/or an electrochemical element for measurement of the oxygen activity of the molten metal
Implementation Method 2
an electrochemical element for measurement of the oxygen activity of the molten metal
Implementation Method 3
a signal line comprising at least two individual wires connected to the sensor unit
Data Source
AI summary
A measuring probe for a molten metal, comprising a sensor unit adapted to determine at least one parameter of the molten metal, a signal line connected to the sensor und and a carrier element. The sensor unit comprises a sensing element and a metal body. The signal line comprises at least two wires and the inner diameter of the carrier tube is between 7 to 20 times the outer diameter of the wires. In a further aspect, the invention relates to a method to measure the at least one parameter of a metal melt.