Reverse-mounted Hammer Tuyere Removal Mechanism

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Solution Overview

Problem

Existing methods for removing tuyeres from blast furnace walls are inefficient, time-consuming, and pose a high risk to operators due to the heavy, press-fit nature of tuyeres and the demanding furnace environment, often resulting in prolonged downtime and costly interruptions.

Innovation Solution

A reverse-mounted hammer system integrated with a slidable frame and elongated lifting arm, attached to a small excavator, applies a pulling motion to the tuyere using the excavator's boom, allowing for efficient and safe removal by directing the hammer's energy into a pulling motion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual methods are used to remove tuyeres, then operator control and flexibility are maintained, but operator injury risk increases and removal time extends

Engineering Contradiction:

Improveoperator safetyVSAvoidremoval speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical removal with an automated hydraulic system. A hydraulic cylinder with a rod and hook automatically engages the tuyere and applies pulling force, eliminating the need for operators to manually handle the heavy, damaged tuyeres while maintaining controlled removal speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a hydraulic cylinder as an intermediary device between the removal system and the tuyere. This intermediary mechanism transfers and amplifies the pulling force while keeping operators at a safe distance, resolving the contradiction between safety and effective removal capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Force

If hydraulic cylinders are used to pull tuyeres, then removal force increases, but device complexity increases

Engineering Contradiction:

Improvepulling forceVSAvoidsystem complexity

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The patent designs the hydraulic cylinder to perform multiple functions: it provides the pulling force to extract the tuyere, and its rod serves as both a structural component and a guide for the hook mechanism. This multi-functionality reduces overall system complexity while maintaining high pulling force capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the hydraulic cylinder, rod, and hook into an integrated assembly where components work together as a unified system. The rod is attached to the hook, and both are part of the same hydraulic mechanism, reducing the number of separate parts and simplifying the overall device structure.

Inventive Principle:

Principle #5Merging (Combining)

3Stability of the object's composition

If hammers are used to vibrate or push tuyeres, then loosening effect is achieved, but pulling direction force is lost

Engineering Contradiction:

Improvetuyere looseningVSAvoidpulling direction force

Core Design Contradiction:

Stability of the object's compositionVSForce

Solution Approach 1:

The patent inverts the traditional hammer approach by positioning the hammer behind the tuyere and using it to push the tuyere outward while the hydraulic cylinder simultaneously pulls. This inverted configuration allows the hammer to assist loosening without compromising the pulling direction force, as both actions work together rather than opposing each other.

Inventive Principle:

Principle #13The other way round (Inversion)

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 solution significantly reduces tuyere removal time from hours to minutes, minimizing downtime costs and enhancing operator safety by reducing the need for multiple operators and manual handling.

Implementation Method 1

reverse mounted hydraulic or pneumatic hammer to provide a pulling motion on the tuyere

Methodology Applied

Scientific EffectImpact force: Impact Force

Data Source

PatentUS9121077B2Tuyere remover

Publication Date: 2015.09.01 TMS INT CORP

AI summary

A component of a gas injection system (tuyere/tymp) removal apparatus comprising a pneumatic or hydraulic hammer reverse mounted into a hammer frame, the working end of the hammer fixedly attached a first end of a slidable frame. The slidable frame having a second end fixedly attached to an elongated lifting arm means with a component handling means, and two sides slidably attached to the hammer frame. The component handling means may be inserted into the rear of a component of a gas injection system. When activated, the hammer generates a pulling motion on the component handling means engaged with the component of a gas injection system, releasing the component of a gas injection system from the wall of the blast furnace.