Sintering Machine Burn-Through Point Control
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Solution Overview
Problem
Existing methods for regulating the burn-through point in sintering machines are costly and unreliable due to the need for multiple sensor measurements, leading to inaccuracies and instability in determining the optimal conveying speed, which can result in incomplete sintering or premature burn-through.
Innovation Solution
A method that uses temperature measurements at three consecutive points along the conveying path to determine the burn-through point by identifying a maximum temperature change, allowing for adjustment of the conveying speed based on the deviation from the desired burn-through point, with a single temperature sensor per measurement point, reducing costs and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature measurements are taken at multiple windboxes to determine the burn-through point, then the reliability of burn-through point detection is improved, but the device complexity and cost increase
Solution Approach 1:
The patent divides the temperature measurement task into three discrete measurement points arranged sequentially along the conveying path. Each measurement point captures temperature at a specific location, and by segmenting the measurement process this way, the system achieves reliable burn-through detection without requiring complex multi-sensor arrangements at every windbox location
Solution Approach 2:
The patent uses temperature measurements from three sequential points to create a temperature profile that copies the thermal state of the material bed. By analyzing the relationship between these three temperature readings (specifically when T2 > T1 and T2 > T3), the system can infer the burn-through point location without directly measuring at every position, thus reducing device complexity while maintaining detection reliability
2Manufacturing precision
If the conveying speed is adjusted based on precise burn-through point determination, then the manufacturing precision of sintering completion position is improved, but the productivity may be reduced due to speed adjustments
Solution Approach 1:
The patent implements a feedback control system where the burn-through point position is continuously monitored using temperature measurements, and the conveying speed is adjusted in real-time based on the deviation from the desired burn-through position. This feedback mechanism ensures precise control of sintering completion location while optimizing productivity by making incremental speed adjustments rather than complete process stops
Solution Approach 2:
The patent makes the conveying speed dynamic rather than fixed. The speed is continuously adapted based on the detected burn-through point position, allowing the system to optimize both precision and productivity. When the burn-through point is ahead of target, speed is reduced; when behind, speed is increased, creating a dynamic balance between precision and production rate
3Measurement precision
If the burn-through point is determined using maximum temperature value from windboxes, then the measurement precision is improved, but the reliability decreases due to temperature fluctuations and external influences
Solution Approach 1:
The patent anticipates potential measurement errors and reliability issues by using three measurement points to create a temperature profile. By analyzing the relative temperatures at these points (specifically the pattern where the middle point is hottest), the system cushions against false readings from any single point, thereby improving reliability while maintaining measurement precision
Solution Approach 2:
The system continuously monitors temperature at three points and uses feedback from this data to reliably determine burn-through. The feedback mechanism analyzes the temperature pattern over time and space, confirming burn-through only when the characteristic temperature profile is detected, which improves reliability by filtering out transient or erroneous temperature spikes
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 approach provides a robust and cost-effective means to accurately adjust the burn-through point, ensuring complete sintering without premature discharge, by analyzing the temperature profile along the conveying path and adjusting the conveying speed accordingly, thereby enhancing production efficiency and reducing the risk of incomplete sintering.
Implementation Method 1
the temperature determined by the temperature of the material to be sintered is measured at at least three measurement points arranged one after the other along the conveying path
Implementation Method 2
the material surface on the sintering machine subsequent to the material intake is ignited, wherein the ignited material subsequently is conveyed on the sintering machine, wherein the material ignited on its surface burns through over the entire height of the material to be sintered
Implementation Method 3
the material ignited on its surface burns through over the entire height of the material to be sintered
Data Source
Figure 1
Figure 2
AI summary
For adjusting the burn-through point (D) in a sintering machine (1), in which the material to be sintered is charged onto a conveying path (3), ignited and transported past windboxes (6) arranged in conveying direction (F) up to a material dump (5), the temperature is measured at at least three measurement points (10) consecutively arranged along the conveying path (3) and the conveying speed of the sintering machine (1) is adjusted in dependence on the position of the maximum measured temperature (D(i)) relative to the position of the selected burn-through point (D) on the conveying path. The profile of the temperature of three consecutively arranged measurement points (10) is compared, wherein a maximum of the temperature is assumed when the first and third measurement points (10) in conveying direction (F) have a lower temperature value than the second measurement point (10), and wherein no maximum of the temperature is assumed when all measurement points (10) form an ascending series of temperature values. With an assumed maximum of the temperature, the conveying speed is adjusted in dependence on a deviation between the position of the measurement point with the maximum temperature value (D(i)) and the position of the selected burn-through point (D), whereas with no assumed maximum of the temperature the conveying speed is reduced by a specified value.