Refractory Anchor Assembly with Resistance Welding
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Solution Overview
Problem
Existing refractory anchor systems, such as hexmetal and hexalt, are time-consuming and costly to install due to their complex designs and require labor-intensive cutting, fitting, and welding, which results in low-quality welds and restricted refractory thickness application.
Innovation Solution
A refractory anchor assembly featuring a base pin assembly with an electrical resistance contact point and multiple anchor legs that can be easily secured to a vessel wall using electrical resistance welding, allowing for faster and higher-quality installation, with a ceramic ferrule for improved weld quality and flexibility in metal composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional hexmetal anchoring systems are used, then robust anchoring is achieved, but installation time and cost increase significantly due to cutting, fitting, and welding requirements
Solution Approach 1:
The hexmetal honeycomb structure is divided into individual anchor components that can be installed separately using resistance welding, eliminating the need to cut and fit large interlocking sheets while maintaining the robust anchoring characteristics of the original system
Solution Approach 2:
The mechanical cutting and fitting process is replaced with electrical resistance welding technology, allowing for faster and more precise installation of anchor components without the time-consuming manual operations required by traditional hexmetal systems
2Ease of operation
If hand welding is used for hexalt anchors, then installation flexibility is maintained, but weld quality deteriorates and installation cost increases
Solution Approach 1:
Hand welding operations are replaced with automated or semi-automated resistance welding processes that provide consistent, high-quality welds while maintaining the flexibility to install anchors in various positions and configurations
Solution Approach 2:
The welding parameters such as current, voltage, and weld time are optimized and controlled in the resistance welding process to achieve consistent high-quality welds, unlike variable hand welding quality
3Reliability
If complex anchor designs are used to achieve reliable anchoring, then anchoring performance is improved, but fabrication difficulty increases
Solution Approach 1:
The anchor system is segmented into standardized components with simplified geometries that are easier to fabricate, while the overall system reliability is maintained through proper component arrangement and resistance welding connections
Solution Approach 2:
The design parameters of anchor components are optimized to balance fabrication ease with anchoring reliability, using standard materials and simplified shapes that can be manufactured efficiently while still providing reliable anchoring when resistance welded
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 anchor assembly provides a reliable and efficient refractory lining system that is easier to install and fabricate, replicating the benefits of hexmetal with reduced installation time and cost, while ensuring high-quality welds and flexibility in metal usage.
Implementation Method 1
The mounting end has an electrical resistance contact point formed thereon
Data Source
AI summary
An anchor assembly for anchoring refractory materials within a vessel is disclosed that provides for a more reliable refractory anchor and resultant refractory lining system that is easier to install both in terms of the refractory lining and the anchor assembly itself when compared to prior art anchor assemblies. The anchor assembly includes a base pin assembly, and at least one anchor leg connected to and extending from the base pin assembly. The base pin assembly includes a mounting end formed on one end of the pin assembly adapted for securing the base pin assembly to the vessel. The mounting end has an electrical resistance contact point formed thereon. The electrical resistant contact point preferably has a flux material located thereon.