Pressure Ring Wedge Connector for Lower Thermal Stress
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Solution Overview
Problem
Existing pressure ring assemblies in electrical metallurgical furnaces face issues with material failure due to thermal stresses and require frequent maintenance, while existing wedge connectors compromise structural integrity and thermal mass when adding bulk for heat management.
Innovation Solution
A pressure ring assembly with removable wedge connectors and pressure ring segments featuring radiused bores and complementary prongs that secure segments in abutting configuration, allowing for even force distribution and reduced material removal, enhancing durability and thermal mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If copper material is used for high thermal conductivity, then heat dissipation capability is improved, but strength and creep resistance deteriorate
Solution Approach 1:
The pressure ring assembly uses composite construction by joining multiple copper segments together with wedge connectors. This allows the copper material to provide high thermal conductivity for heat dissipation while the segmented structure with mechanical connectors provides the necessary strength and creep resistance that pure copper lacks.
2Temperature
If heavier pressure ring with more copper mass is used for heat soaking, then thermal mass and heat absorption capability are improved, but structural integrity and ease of maintenance deteriorate
Solution Approach 1:
The pressure ring is divided into multiple separable copper segments joined by wedge connectors. This segmentation maintains the thermal mass benefit of heavy copper construction while enabling easy maintenance - segments can be independently removed and replaced without requiring complete disassembly of the entire pressure ring assembly.
3Ease of manufacture
If outer peripherally mounted inter-segment wedge connector is used, then clamping mechanism functionality is achieved, but pressure ring segment body material must be extensively removed
Solution Approach 1:
The wedge connector is repositioned from an external peripheral mounting to an internal location where it fits within the bore structure of the pressure ring segments. This dimensional relocation eliminates the need for extensive material removal while maintaining the clamping functionality, as the wedge operates within the existing bore geometry rather than requiring external attachment features.
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 solution enables efficient assembly and disassembly, reduces stress concentrations, and maintains structural integrity by distributing clamping forces evenly, minimizing deformation and extending maintenance intervals.
Implementation Method 1
mutually facing contact faces on the prongs configured to engage the radiused wall section of the bores... the mutually facing contact faces of the first and second prongs abut against the radiused wall sections, thereby mechanically securing the first and second pressure ring segments
Implementation Method 2
having a heavier pressure ring than that of WO2005/071335 could be advantageous in that the shear mass of copper can soak up vast amounts of heat energy and effectively transfer the heat to internal water passages for the heat to be removed
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A pressure ring assembly (10) comprises at least first and second segments 12.1, 12.2 which are connected to one another in abutting relationship by a removable wedge connector 14 comprising first and second prongs 36, 38. Each segment comprises a body 20 extending arcuately between first and second side walls 22, 24 thereof. Each segment defines first and second elongate bores 26, 28. Each bore has a radiused wall section 30 facing the adjacent side wall, the radius being at least 15 mm. The first and second prongs diverge away from one another at an angle of less than 15 degrees. The first prong extends into the second bore of the first segment and the second prong extends into the first bore of the second segment. Mutually facing contact faces 46, 48 of the first and second prongs have profiles complementary to the radiused wall sections 30 of the bores.