Robotic Refractory Removal System with Multi-Axis Nozzle Control
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Solution Overview
Problem
The removal of refractory linings from vessels is a laborious and hazardous task, often requiring high-pressure hydro-demolition systems that lack precision control and necessitate operators to be inside the vessel, posing safety risks and inefficiencies.
Innovation Solution
A refractory removal system with top and bottom assemblies, including a nozzle assembly that provides rotation, axial, and linear actuation mechanisms, allowing for precise control and reduced pressure (up to 10,000 PSI or less) and flow rate (up to 100 gallons/minute or less) operations, enabling safe and efficient removal without an operator inside the vessel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-pressure hydro-demolition systems are used to remove refractory linings, then removal effectiveness is improved, but safety deteriorates due to operators needing to be inside the vessel
Solution Approach 1:
A robotic manipulator system acts as an intermediary between the operator and the refractory lining removal process. The operator controls the robotic arm from outside the vessel, allowing high-pressure water jet application while eliminating the need for human presence in the hazardous environment inside the vessel.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robotic system. The robotic manipulator, controlled by a operator outside the vessel, substitutes for direct human mechanical intervention, thereby improving safety while maintaining removal effectiveness.
2Object-affected harmful factors
If traditional removal methods are used, then operator safety is improved by eliminating inside-vessel operations, but productivity deteriorates due to laborious manual processes
Solution Approach 1:
Manual labor is replaced with an automated robotic manipulator system that can apply high-pressure water jets with precision and consistency, significantly improving removal efficiency while keeping operators outside the vessel for safety.
Solution Approach 2:
The robotic system enables self-service operation where the manipulator autonomously positions and operates the water jet under remote control, eliminating the need for operators to physically enter the vessel while maintaining high productivity through automated precision operations.
3Productivity
If heavy equipment like jackhammers is used for refractory removal, then removal capability is improved, but device complexity and safety worsen due to equipment size and operator exposure
Solution Approach 1:
Heavy mechanical impact equipment like jackhammers is replaced with a high-pressure water jet system mounted on a robotic manipulator. This substitution reduces equipment complexity while maintaining or improving removal capability, and eliminates the need for operators to handle heavy equipment inside the vessel.
Solution Approach 2:
The patent employs hydraulic high-pressure water jets as the primary removal mechanism, replacing heavy mechanical impact equipment. This hydraulic approach achieves effective refractory removal with less complex, lighter equipment that can be precisely controlled by the robotic system.
4Productivity
If high-pressure and high-flow rate systems are used, then removal effectiveness is improved, but energy consumption and operational cost worsen
Solution Approach 1:
The robotic manipulator enables localized, targeted application of high-pressure water jets only where refractory material needs removal. This precision control prevents waste of energy on unnecessary areas, allowing effective removal with reduced overall energy consumption compared to indiscriminate high-pressure applications.
Solution Approach 2:
The system dynamically adjusts the water jet parameters and manipulator positioning based on real-time requirements. This dynamic control allows the system to use high pressure only when and where necessary, optimizing energy consumption while maintaining removal effectiveness throughout the refractory lining.
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 allows for precise and efficient removal of refractory materials with reduced pressure and flow rates, enhancing safety by eliminating the need for operators inside the vessel and improving operational efficiency through modular design and adjustable components.
Implementation Method 1
refractory removal systems and methods utilizing hydrodemolition
Data Source
AI summary
An improved refractory removal system may provide a top, bottom, and nozzle assemblies. At least one of the top or bottom assemblies may provide a rotation mechanism that allows a nozzle or the nozzle assembly to be rotated about a central axis or axis of rotation. The system may provide one or more securing mechanism(s) that allow the system to be secured in a desired position of a refractory vessel that refractory material is to be removed from. The nozzle assembly may provide an axial actuation mechanism that allows the nozzle to be moved away or towards the central axis. The nozzle assembly may also provide a linear actuation mechanism that allows the nozzle to be moved up or down along the central axis. It shall be recognized that the system provides at least three degrees of motion to the nozzle, thereby allowing the system to be utilized for a variety of situations.