Steel Scale Composition Detection Using Dual-Wavelength Pyrometry
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Solution Overview
Problem
Current methods for determining the composition of scales on steel materials during operation are not accurate and cannot be performed in real-time, relying on model equations and requiring physical samples for analysis.
Innovation Solution
A scale composition determination system using radiation thermometry to measure temperatures at multiple wavelengths, allowing for the identification of hematite (Fe2O3) in the outermost layer of the scale based on temperature differences, enabling online determination of scale composition without the need for physical samples.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If X-ray diffraction measurement is used to determine scale composition, then measurement precision is improved, but productivity deteriorates due to requirement of fabricating test pieces and cooling the steel material before measurement
Solution Approach 1:
The patent replaces the mechanical/X-ray based measurement system with a radiation thermometry system. Instead of using X-ray diffraction measurement that requires cutting test pieces and cooling the material, the invention uses optical radiation measurement to detect temperature differences at multiple wavelengths, enabling non-contact, real-time scale composition determination during the hot rolling process without interrupting production
Solution Approach 2:
The patent changes the measurement parameter from X-ray diffraction patterns to thermal radiation characteristics at multiple wavelengths. By measuring temperature at two or more different wavelengths and analyzing the temperature difference, the system can determine scale composition (single-layer vs. multilayer) without requiring the material to be cooled or cut, thus achieving online real-time determination
2Productivity
If model equations are used to determine oxidation rate-determining process, then scale composition can be determined, but measurement precision deteriorates due to reliance on model accuracy and multiple assumptions
Solution Approach 1:
The patent replaces the model-equation-based determination method with a direct physical measurement approach using radiation thermometry. Instead of calculating oxidation rates through model equations that require multiple assumptions about initial oxide layer thickness and model constants, the invention directly measures temperature at multiple wavelengths and determines scale composition from the temperature difference, eliminating the need for complex modeling and improving measurement accuracy
Solution Approach 2:
The patent uses radiation thermometry to create a thermal signature copy of the scale layer. By measuring the thermal radiation characteristics at multiple wavelengths, the system creates a temperature profile that directly reflects the scale composition without needing to model the oxidation process, thereby improving precision while maintaining online determination capability
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
Accurately determines the composition of scales on steel materials during operation, preventing flaws and improving operational management by identifying single-layer or multilayer scales in real-time.
Implementation Method 1
a measurement means that measures temperatures of the steel material at two wavelengths different from each other by radiation thermometry
Data Source
AI summary
A scale composition determination device (10) determines that Fe2O3 has been generated in the outermost layer of a scale (SC) in the case where the absolute value of a difference between temperatures of a steel material SM measured by radiation thermometers (20a, 20b) is equal to or more than a predetermined temperature, and determines that Fe2O3 has not been generated in the outermost layer of the scale (SC) in the case where the absolute value of the difference between the temperatures of the steel material SM measured by the radiation thermometers (20a, 20b) is not equal to or more than the predetermined temperature.