Ultrasonic Crystallizer Sensor for Continuous Casting
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Solution Overview
Problem
Current methods for measuring the level and temperature of molten metal in continuous casting machines face challenges such as the use of radioactive sources, limited accuracy of electromagnetic sensors, and the need for thermocouple insertion, which are hazardous, less accurate, or applicable only to specific thicknesses of crystallizers.
Innovation Solution
A non-invasive ultrasonic detection system that uses piezoelectric ceramic transducers to measure the position of the meniscus and temperature of the crystallizer by transmitting and receiving ultrasonic waves, allowing for precise measurements without radioactive sources and suitable for various crystallizer thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If radioactive sensors are used to measure the level of liquid metal, then measurement precision is improved, but safety hazards and disposal costs increase
Solution Approach 1:
The patent replaces the radioactive measurement system with an acoustic measurement system. Acoustic waves are transmitted through the crystallizer wall, and the reflection characteristics are analyzed to determine the liquid metal level. This substitution eliminates all radioactive hazards while maintaining measurement precision through acoustic impedance differences between liquid metal and gas phases.
Solution Approach 2:
The patent introduces acoustic waves as an intermediary medium to transfer information about the liquid metal level. The acoustic waves interact with the liquid metal surface and the crystallizer wall, carrying measurement information back to the sensors without requiring direct contact with the hazardous radioactive sources.
2Object-affected harmful factors
If electromagnetic sensors are used to measure the level of liquid metal, then safety hazards are reduced, but measurement precision deteriorates
Solution Approach 1:
The patent replaces electromagnetic sensing with acoustic sensing. The acoustic method utilizes sound wave propagation and reflection characteristics, which are not affected by the electrical conductivity issues that limit electromagnetic sensor precision. This provides both safety and improved measurement accuracy.
3Temperature
If thermocouples are inserted into the crystallizer to measure temperature, then temperature measurement is achieved, but the crystallizer structure is compromised and applicability is limited to specific thicknesses
Solution Approach 1:
The patent replaces contact-based thermocouple measurement with non-contact acoustic measurement. Acoustic wave propagation speed through the crystallizer wall varies with temperature, allowing temperature measurement without physical penetration. This preserves crystallizer structural integrity and eliminates thickness limitations.
Solution Approach 2:
The patent uses acoustic waves as an intermediary to measure temperature through the crystallizer wall. The acoustic properties of the wall material change with temperature, providing measurement information without requiring thermocouples to be inserted into the crystallizer structure.
4Temperature
If thermocouples are inserted into the crystallizer, then temperature measurement is achieved, but installation complexity and maintenance costs increase
Solution Approach 1:
The patent replaces the complex thermocouple insertion and wiring system with external acoustic transducers. The acoustic measurement system requires no penetration of the crystallizer wall, eliminating installation complexity and maintenance issues associated with thermocouples in harsh molten metal environments.
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, precise, and reliable measurements of the meniscus position and temperature, reducing installation and management costs while avoiding the hazards of radioactive materials and being applicable to both thin and thick crystallizers.
Implementation Method 1
at least one first ultrasonic element (16) configured as a transmitter of a transmission ultrasonic elastic wave (40)
Implementation Method 2
at least one second ultrasonic element (20) configured as a receiver of a received ultrasonic elastic wave (42)
Implementation Method 3
a phase of transmission of at least one transmission ultrasonic elastic wave (40) by means of at least one first ultrasonic element (16)
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Measuring method, measuring system, measuring sensor for measuring a physical quantity in a crystallizer of a continuous casting machine of a liquid metal based on the transmission of at least one detection signal transmitted towards the crystallizer and a phase of reception of at least one received measuring signal dependent on the transmitted detection signal and mould and continuous casting machine provided with said measuring system.