Projected Anchor Layout Using Diffracted Light Patterns
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Solution Overview
Problem
The process of installing refractory anchors in high-temperature vessels is time-consuming and costly due to the need for manual layout and replacement, which involves shutting down facilities for extended periods, resulting in significant economic losses.
Innovation Solution
A light-projecting system that projects light indicia patterns onto the installation surface to accurately identify installation locations for refractory anchors, utilizing a light module with a diffractive optical element and adjustable mechanisms to ensure precise spacing, allowing for faster and more efficient anchor placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual measuring and chalk-line tools are used to mark anchor locations, then installation precision can be achieved, but installation time becomes excessively long
Solution Approach 1:
The patent replaces the manual mechanical layout system (measuring tools and chalk lines) with an optical projection system that uses a laser module and diffractive optical element to automatically project light indicia patterns onto the installation surface, directly indicating anchor locations without manual measurement
Solution Approach 2:
The patent creates a visual copy of the anchor layout pattern by projecting light indicia that replicate the desired anchor arrangement onto the installation surface, allowing workers to directly follow the projected pattern rather than interpreting manual chalk lines
2Reliability
If refractory anchors are installed in high-temperature vessels, then structural integrity is protected, but installation and replacement require facility shutdown causing economic loss
Solution Approach 1:
The patent enables preliminary positioning and layout of anchor locations using the light projection system before actual anchor installation begins, allowing for more efficient installation proceedings and reduced overall installation time that translates to shorter facility shutdowns
3Manufacturing precision
If skilled craftspersons perform layout tasks with advanced technical understanding, then anchor spacing accuracy is ensured, but labor complexity and training requirements increase
Solution Approach 1:
The patent makes the layout system self-explanatory and self-guiding by projecting visual light indicia patterns that directly show anchor locations and spacing requirements, eliminating the need for workers to interpret technical drawings or understand complex layout patterns, thereby reducing skill requirements
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 system significantly reduces installation time and costs by enabling rapid and accurate placement of refractory anchors, minimizing downtime and improving the efficiency of refractory lining replacement and new facility start-ups.
Implementation Method 1
a diffractor (e.g., a diffractive optical element) that diffuses the source light beam into the multiple light beams
Data Source
AI summary
A light module projects multiple light beams onto an installation surface to form multiple light indicia spaced apart in a pattern on the installation surface, with the light indicia identifying installation locations on the installation surface where construction mounts are then installed. Embodiments include systems in which the light module includes a light emitter that projects a source light beam and a diffractor that diffuses the source light beam into the multiple light beams, systems in which the light module is adjustably mounted to and movable with a handheld tool used to install the construction mounts, systems in which the light module is adjustably mounted to a static-use support, and methods of using these systems to install the construction mounts.