Remote Calcium Carbide Tapping Control via Centralized Manipulators
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Solution Overview
Problem
Current mechanization of calcium carbide tapping work near electric furnaces lacks safety and efficiency, particularly when handling multiple tap dents in parallel, as existing systems rely on visual feedback and do not facilitate integrated management of operations across multiple dents.
Innovation Solution
A remote control system is developed, utilizing monitoring cameras to image tap dent situations and sound collectors to transmit arc sounds, along with manipulators and ladle feeding apparatuses, to enable safe and efficient operation of tapping machines across multiple tap dents from a centralized or sub-operation rooms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a manipulator is used for tapping work, then the safety of workers is improved by reducing direct exposure to high temperature, but the ability to conduct integrated management of multiple tap dents is worsened due to lack of centralized control
Solution Approach 1:
The patent combines multiple manipulators and their control systems into a centralized control system located in a control room. This allows integrated management of multiple tap dents while maintaining worker safety through remote operation. The centralized system consolidates control functions for multiple manipulators, enabling coordinated operation and monitoring of all tapping activities from a single location.
Solution Approach 2:
The patent introduces a control room as an intermediary between operators and the manipulators at the tap dents. This intermediary provides visual monitoring capabilities and centralized control functions, allowing operators to manage multiple manipulators remotely without direct exposure to high-temperature environments. The control room serves as a mediator that bridges the gap between human operators and the automated tapping equipment.
2Ease of operation
If visual sensation-based control is used, then the ease of operation is improved, but the productivity for handling multiple tap dents in parallel is worsened due to inability to monitor all dents simultaneously
Solution Approach 1:
The patent uses visual monitoring systems (cameras and displays) to create visual copies or representations of the tap dent environments in the control room. This allows operators to view and control multiple tap dents simultaneously through displayed images rather than direct visual observation. The visual copying mechanism enables parallel monitoring and control of multiple tapping operations without requiring operators to be physically present at each location.
3Reliability
If remote control system is implemented, then the safety is improved by eliminating direct exposure to high temperature, but the loss of information about work conditions is worsened due to reduced sensory feedback
Solution Approach 1:
The patent implements visual feedback systems through cameras and monitors that provide real-time images of the tap dent conditions to operators in the control room. This feedback mechanism compensates for the loss of direct sensory feedback by transmitting visual information about the work environment, carbide flow conditions, and manipulator positions. The feedback system enables operators to make informed decisions and adjustments based on real-time visual information without being physically exposed to high-temperature environments.
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 system allows for safe and efficient mechanized tapping work at an industrial scale by providing real-time monitoring and collective management of tap dent operations, enhancing worker safety and productivity.
Implementation Method 1
monitoring camera to image the situation at each tap dent
Implementation Method 2
sound collector to collect the arc sounds generated when each tap dent is opened
Implementation Method 3
a heat temperature against the graphite bar is generated by the arc discharge
Data Source
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AI summary
Disclosed is a remote control system for tapping calcium carbide, which can safely and efficiently conduct a tapping work. The remote control system for tapping calcium carbide, which includes an electric furnace (101) for producing calcium carbide, tapping machines (102) which are retainable and releasable tapping tools (here, the tapping tools include a graphite bar used at an opening step and having a diameter between 50 and 100 mm, a sticking rod used at a taking step, having a portion which is inserted into the electric furnace and a diameter thereof is between 20 and 80 mm, and a dent sealing unit used at a dent sealing step which can contain a clay having a volume between 1000 and 4000 cm3), monitoring cameras (103), one or a plurality of manipulators for manipulating the respective tapping machines (102), and a main tapping operation room including a monitor (120).