Refractory Lining Wear Measurement with Dual Laser Scanners
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Solution Overview
Problem
Existing methods for measuring wear of refractory linings in receptacles containing molten metal, such as ladles and electric arc furnaces, are inaccurate due to shadow zones created by slag rims and require complex merging of partial 3D images, leading to incomplete and less precise wear analysis.
Innovation Solution
Utilizing two laser scanners positioned to provide overlapping views of the refractory lining, allowing for simultaneous scanning and merging of data to create a comprehensive 3D image, which includes areas obscured by deposits, thereby enhancing accuracy and resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single laser scanner is used to scan the refractory lining, then the device complexity is low, but the measurement precision is insufficient due to shadow zones created by slag rims
Solution Approach 1:
The refractory lining surface is divided into multiple scan zones, with different laser scanners positioned to scan different zones. The first laser scanner scans areas not obscured by slag rims, while the second laser scanner scans shadow zones from a different angle, eliminating measurement gaps through spatial segmentation of the scanning task
Solution Approach 2:
The solution transitions from a single scanning position to multiple scanning positions in three-dimensional space. By positioning laser scanners at different locations and angles around the receptacle, the system captures the refractory lining surface from multiple dimensions, eliminating shadow zones and achieving complete surface coverage
2Measurement precision
If multiple laser scanners are used to cover shadow zones, then the measurement precision improves, but the device complexity increases
Solution Approach 1:
The scanning system is segmented into multiple independent laser scanners, each responsible for specific zones of the refractory lining. This segmentation allows each scanner to operate independently in its optimal position while collectively achieving complete coverage, balancing precision improvement with manageable system complexity
Solution Approach 2:
Multiple laser scanners perform the same basic function of emitting and receiving laser beams to measure surface topography, but are positioned at different locations to serve different scanning purposes. This multi-functionality approach allows the system to maintain consistent measurement capabilities across all zones without requiring fundamentally different measurement technologies
3Measurement precision
If the laser scanner is positioned close to the receptacle to get detailed views, then the measurement precision improves, but the reliability decreases due to heat exposure
Solution Approach 1:
The laser scanners are positioned at a safe distance from the hot receptacle surface, utilizing three-dimensional spatial arrangement to achieve both detailed measurement and thermal protection. By optimizing the distance and angle of scanner positioning, the system maintains measurement precision while ensuring scanner reliability through adequate thermal separation
4Area of stationary object
If successive 3D images are merged from multiple scanner positions, then the area coverage improves, but the measurement precision decreases due to merging complexity
Solution Approach 1:
The system merges 3D images from multiple laser scanners by establishing coordinate transformations between different scanner reference frames. Through merging processing that aligns and integrates data from all scanners, the system achieves complete surface coverage while maintaining measurement precision through coordinated data fusion rather than simple concatenation
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 method provides a more accurate and efficient measurement of wear by ensuring complete coverage of the refractory lining, reducing exposure time to harsh environments, and enabling precise detection of wear and deposit zones.
Implementation Method 1
a laser beam emitter adapted to emit a laser beam towards the refractory lining
Implementation Method 2
a laser beam receiver adapted to receive the reflected laser beam
Implementation Method 3
measuring a transit time between emission of the laser beam and reception of the reflected laser beam
Data Source
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AI summary
Process for measuring wear of a refractory lining (1) of a receptacle (2) intended to contain molten metal, comprising the following steps: - scanning a first surface (4A) of the refractory lining using a first laser scanner (21A) in order to obtain a first initial set of data representative of the first surface, - scanning a second surface (4B) of the refractory lining using a second laser scanner (21B), distinct from the first laser scanner, in order to obtain a second initial set of data representative of the second surface, wherein the second surface includes a grey zone (6B) for the first laser scanner, the receptacle defining an obstacle (3) located between the first laser scanner and the grey zone during scanning by the first laser scanner, and - calculating a final set of data using the first initial set of data and the second initial set of data, the final set of data being representative of a surface (4) of the refractory lining including the first surface and the second surface.