Optical Cored Wire Temperature Measurement Optimization

Solution Overview

Problem

Existing methods for determining temperature values in molten metal baths during the metal making process are inefficient, leading to unnecessary measurements and excessive consumption of optical cored wire due to lack of consideration for the final end temperature and changing conditions.

Innovation Solution

A method using a model F(t) to describe temperature development over time, defining a critical temperature value, and calculating a fitted heating rate to optimize the timing and number of measurements, ensuring the molten metal bath reaches the final end temperature with minimal wire consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the optical cored wire is immersed deeper into the molten metal bath to ensure accurate temperature measurement, then measurement precision is improved, but the consumption of optical cored wire increases and flotational forces increase

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidoptical cored wire consumption

Core Design Contradiction:

Measurement precisionVSLoss of substance

Solution Approach 1:

The patent applies preliminary action by calculating the future time point tcal(n+1) before the next measurement is taken. The system predicts when the critical temperature will be reached based on current temperature Tmes(n) and heating rate Rheat(n), allowing the operator to schedule the next measurement at the optimal moment without needing to increase immersion depth. This prevents unnecessary wire consumption while maintaining measurement accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback by continuously monitoring the temperature Tmes(n) and using it to update the model F(t) and calculate the heating rate Rheat(n). This feedback loop allows the system to adapt the measurement timing based on actual temperature development, ensuring measurements are taken at optimal moments when the temperature is approaching the critical value, thereby reducing the need for deep immersion and minimizing wire consumption.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If temperature measurements are taken frequently to monitor the metal making process, then process control accuracy is improved, but the consumption of optical cored wire increases

Engineering Contradiction:

Improveprocess control accuracyVSAvoidoptical cored wire consumption

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent applies preliminary action by calculating the future time point tcal(n+1) before the next measurement is taken. The system predicts when the critical temperature will be reached based on current temperature Tmes(n) and heating rate Rheat(n), allowing the operator to schedule the next measurement at the optimal moment without needing to increase immersion depth. This prevents unnecessary wire consumption while maintaining measurement accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies parameter changes by dynamically adjusting the timing of measurements based on the current temperature Tmes(n) and calculated heating rate Rheat(n). Instead of taking measurements at fixed intervals, the system adjusts the time interval based on the actual temperature development and proximity to the critical temperature, optimizing both process control and wire consumption.

Inventive Principle:

Principle #35Parameter changes

3Ease of repair

If the optical cored wire is retracted after each measurement, then the wire can be reused, but the tip becomes the new leading tip and measurement continuity is affected

Engineering Contradiction:

Improvewire reuse capabilityVSAvoidmeasurement continuity

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The patent applies preliminary action by calculating the future time point tcal(n+1) before the next measurement is taken. The system predicts when the critical temperature will be reached based on current temperature Tmes(n) and heating rate Rheat(n), allowing the operator to schedule the next measurement at the optimal moment without needing to increase immersion depth. This prevents unnecessary wire consumption while maintaining measurement accuracy.

Inventive Principle:

Principle #10Preliminary action

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 approach allows for accurate and efficient determination of temperature values, minimizing the number of measurements and wire consumption while preventing overheating or underheating, thereby optimizing the metal making process.

Implementation Method 1

the optical fiber can convey thermal radiation received from the molten metal to a detector, e.g. a pyrometer

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS20240003758A1Method and system for determining a series of temperature values of a molten metal bath

Publication Date: 2024.01.04 HERAEUS ELECTRO NITE INT NV

AI summary

The present invention relates to a method and a system for determining a series of at least two temperature values of a molten metal bath with a device comprising an optical cored wire and a detector. The method according to the invention has been proven to be especially suitable for multiple repeated measurements, wherein a final end temperature of the molten metal bath shall be reached.