Measuring Probe Sensor Fixing for Molten Metal Accuracy

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Solution Overview

Problem

Existing measuring probes for molten metal or slag face challenges in accurately fixing and optimizing the positioning of thermocouples and electrochemical sensors, leading to suboptimal measurement accuracy due to shared fixing materials and potential thermal shock issues.

Innovation Solution

The arrangement of a metal strip bath contact around both the thermocouple and electrochemical sensor creates separate chambers, allowing for distinct fixing materials and improved alignment, with the bath contact forming a closed line around both components, and a self-supporting connector module for separate manufacturing and easy integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single fixing material is used for both thermocouple and electrochemical sensor, then the device structure is simplified, but the measurement accuracy and adaptability to different sensor types deteriorate

Engineering Contradiction:

Improvefixing structureVSAvoidsensor measurement accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent divides the fixing structure into separate chambers: a first chamber for the thermocouple and a second chamber for the electrochemical sensor. Each chamber can be filled with appropriate fixing material tailored to the specific sensor type, allowing optimized fixation without compromising measurement accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different fixing materials are applied to different locations (chambers) based on the specific requirements of each sensor type. The first chamber uses materials suitable for thermocouple fixation while the second chamber uses materials optimized for electrochemical sensor fixation, achieving local optimization of fixing quality.

Inventive Principle:

Principle #3Local quality

2Device complexity

If thermocouple and electrochemical sensor are arranged side by side without separation, then the device structure is simplified, but thermal shock protection deteriorates

Engineering Contradiction:

Improvesensor arrangementVSAvoidthermal shock

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent segments the sensor arrangement into separate chambers for the thermocouple and electrochemical sensor. This spatial separation protects the thermocouple from thermal shock by isolating it from direct exposure to extreme temperature fluctuations in the molten metal, while still maintaining a compact overall structure.

Inventive Principle:

Principle #1Segmentation

3Measurement precision

If separate chambers are formed for thermocouple and electrochemical sensor, then fixing material optimization is improved, but device complexity increases

Engineering Contradiction:

Improvesensor fixation optimizationVSAvoidchamber structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into the single measuring head structure: both the thermocouple and electrochemical sensor are integrated into one head with separate chambers. The bath contact serves dual purposes by forming separation walls for both chambers and providing electrical contact. This merging approach achieves sensor optimization without proportionally increasing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If bath contact is arranged to surround both sensors, then gas management for electrochemical sensor is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvegas evacuationVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The bath contact is designed to perform multiple functions simultaneously: it provides electrical contact for the electrochemical sensor, forms the separation wall between chambers, and creates the closed-loop gas evacuation path. This multi-functionality improves gas management reliability while minimizing the number of separate components that would complicate manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

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 configuration enhances measurement accuracy by optimizing the fixing materials for each sensor type and protecting the thermocouple from thermal shock, while ensuring effective gas management for the electrochemical sensor, resulting in improved reliability and precision.

Implementation Method 1

a thermocouple

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a thermocouple

Methodology Applied

Scientific EffectSeebeck effect: Seebeck Effect

Implementation Method 3

The electrochemical sensor can in particular be a solid electrolyte-based oxygen sensor

Methodology Applied

Scientific EffectElectrochemical reaction: Electrochemiluminescence

Data Source

PatentEP2728352B1Measuring probe for measurements in melted metal or slag

Publication Date: 2018.08.15 HERAEUS ELECTRO NITE INT NV

Figure 1a~1c
Figure 2
Figure 3

AI summary

The measuring probe has an oxygen sensor (2) and a thermocouple portion (3) that are arranged in parallel with each other at the immersion end of a measuring head and are projected from the immersion end. The oxygen sensor and thermocouple portion are surrounded with a bath contact portion (4). The bath contact portion is formed from a metal strip. Two chambers are formed at immersion end and opened between thermocouple portion and oxygen sensor, where one chamber is positioned with thermocouple portion and other chamber with sensor by a fixing material.