Pressure Ring Wedge Connector for Low-Stress Furnace Maintenance
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Solution Overview
Problem
Existing pressure ring assemblies in electrical metallurgical furnaces face challenges with material failure due to thermal stresses and the need for efficient maintenance, particularly when using copper or copper alloys, which have low strength and creep over time, and the clamping mechanisms of existing designs require significant material removal for fitting.
Innovation Solution
A pressure ring assembly with removable wedge connectors that secure pressure ring segments using complementary radiused wall sections and prongs, allowing for even force distribution and reduced material loss during assembly, enhancing durability and thermal mass retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If copper or copper alloys are used for pressure ring assembly, then thermal conductivity and heat resistance are improved, but strength and creep resistance deteriorate
Solution Approach 1:
The pressure ring assembly uses a composite structure combining copper segments (for thermal conductivity and heat resistance) with steel wedge connectors (for strength and creep resistance). This allows the system to simultaneously achieve excellent thermal performance and mechanical strength by integrating materials with complementary properties.
2Quantity of substance
If a heavier pressure ring with more copper mass is used, then thermal mass and heat absorption capacity are improved, but material removal for connector fitment increases
Solution Approach 1:
The pressure ring is divided into multiple segments that can be assembled around the electrode. This segmentation allows the wedge connectors to be positioned at the joints between segments rather than requiring extensive material removal from a continuous ring, thereby preserving copper thermal mass while accommodating the connection mechanism.
Solution Approach 2:
The wedge connectors are designed to fit into recesses or bores within the copper segments, with the connector structure nested within the segment geometry. This nesting approach minimizes the volume of copper that must be removed for fitment while still providing adequate space for the steel connector components.
3Ease of repair
If a removable wedge connector design is used, then ease of maintenance and repair are improved, but structural complexity increases
Solution Approach 1:
The wedge connector design allows the pressure ring assembly to transition between a closed operational state and an open maintenance state. The removable wedge connectors enable dynamic reconfiguration of the assembly, allowing segments to be separated for maintenance and then reassembled, providing operational flexibility despite the added structural complexity.
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 fast and efficient maintenance with reduced downtime, maintains structural integrity, and distributes clamping forces evenly, minimizing stress concentrations and material deformation.
Implementation Method 1
the at least one web formation extends through the second slit of the first segment and the first slit of the second segment; and 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
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.