Ultrasonic Sensor for Crystallizer Level and Temperature
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Solution Overview
Problem
Existing sensors for measuring the level of liquid metal in continuous casting machines face challenges such as the handling of radioactive sources, limited accuracy and speed of electromagnetic sensors, and the need for thermocouples which can weaken the crystallizer structure.
Innovation Solution
A sensor system using ultrasonic waves to measure the level of liquid metal and temperature within the crystallizer, eliminating the need for radioactive sources and allowing precise measurements even in thick crystallizers without inserting thermocouples.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If radioactive sensors are used to measure liquid metal level, then measurement precision is improved, but safety hazards and handling complexity increase
Solution Approach 1:
The patent replaces radioactive sensing with ultrasonic wave-based sensing. The ultrasonic sensor emits acoustic waves that propagate through the crystallizer wall to detect liquid metal level, eliminating the need for radioactive sources while maintaining measurement capability through acoustic impedance differences between solid and liquid phases.
Solution Approach 2:
The patent introduces the crystallizer wall as an intermediary medium for wave propagation. Instead of direct contact sensing, ultrasonic waves travel through the crystallizer wall to reach the liquid metal, allowing indirect measurement that avoids safety hazards while preserving measurement precision.
2Object-affected harmful factors
If electromagnetic sensors are used to measure liquid metal level, then safety is improved, but measurement precision and response speed deteriorate
Solution Approach 1:
The patent substitutes electromagnetic sensing with acoustic wave-based sensing. Ultrasonic waves provide more precise and faster response measurements compared to electromagnetic methods, while maintaining safety by avoiding radioactive sources. The acoustic impedance contrast between solid crystallizer and liquid metal enables superior detection accuracy.
3Temperature
If thermocouples are inserted into the crystallizer to measure temperature, then temperature measurement capability is improved, but crystallizer structure strength deteriorates
Solution Approach 1:
The patent replaces contact-based thermocouple temperature measurement with non-contact ultrasonic thermometry. By measuring the speed of sound in the crystallizer material, which varies with temperature, the system obtains temperature data without physical insertion, thereby preserving crystallizer structural integrity and strength.
Solution Approach 2:
The patent uses the crystallizer wall itself as the sensing medium. Ultrasonic waves propagate through the crystallizer material, and the speed of sound serves as an indirect indicator of temperature. This intermediary approach allows temperature monitoring without compromising the crystallizer structure.
4Measurement precision
If ultrasonic waves are used to measure through thick crystallizers, then measurement capability is improved, but wave attenuation increases
Solution Approach 1:
The patent employs pulsed ultrasonic wave transmission rather than continuous waves. By sending periodic pulses and measuring the time-of-flight or echo characteristics, the system can detect liquid metal level and temperature through thick crystallizer walls while managing energy loss through optimized pulse timing and amplitude.
Solution Approach 2:
The patent adjusts ultrasonic wave parameters such as frequency, amplitude, and pulse duration to optimize penetration through thick crystallizer walls. By selecting appropriate frequency ranges and adjusting transmission power, the system overcomes attenuation effects while maintaining measurement precision for level and temperature detection.
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 provides accurate and precise measurements of the liquid metal level and crystallizer temperature, enhancing the reliability and sensitivity of the measurement process while reducing installation and management costs.
Implementation Method 1
A sensor (1) containing at least one ultrasonic element (15, 18, 21, 24, 27, 30) is provided, which is aimed at emitting elastic waves in a direction essentially orthogonal with respect to a wall (48, 49) of the crystallizer (35)
Implementation Method 2
The sensor (1) is aimed at reading the reflected elastic waves
Data Source
AI summary
A system of detection of a temperature of a crystallizer or a level of liquid metal in the crystallizer has a sensor positioned within a mould of the crystallizer. The sensor has a case, a closing cover positioned at a detection face of the case, a plurality of ultrasonic elements arranged in vertically spaced relation to a length of the case, and a plurality of attenuation elements positioned sideways with respect to the closing cover. The plurality of ultrasonic elements include a first ultrasonic element, a second ultrasonic element and a third ultrasonic element positioned in orthogonal relation to the length of the sensor. The plurality of ultrasonic elements transmit and receive ultrasonic waves.