Vertical Electrode Addition Tong with Torque Control
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Solution Overview
Problem
Conventional methods for joining graphite electrodes in metal arc furnaces are time-consuming and hazardous due to manual torque application, leading to variability in torque values and potential joint failure, which can result in equipment damage or injury.
Innovation Solution
A vertical automatic addition tong apparatus that includes a bail and a body with angular and axial movement capabilities, utilizing camming action to grip and lift electrodes, allowing for controlled rotation and axial translation during the joining process, thereby maintaining consistent torque application and reducing axial stress on the electrodes and lifting devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual torque application is used to join electrodes, then the joining process can be performed with simple equipment, but the torque values vary and joint failure may occur
Solution Approach 1:
The patent replaces manual mechanical torque application with an automated mechanical system featuring a torque wrench mechanism that applies consistent torque through a controlled rotation and engagement process, eliminating human variability while maintaining mechanical simplicity
Solution Approach 2:
The patent changes the torque application parameter from manual variable torque to controlled consistent torque through the torque wrench mechanism, ensuring reliable joint engagement by maintaining torque within a specific range throughout the joining process
2Productivity
If manual wrench operation is used for electrode joining, then the device complexity is low, but the operation is time-consuming and hazardous
Solution Approach 1:
The patent substitutes manual wrench operation with an automated torque wrench mechanism that performs the joining operation automatically, increasing productivity by eliminating manual intervention while keeping the device structure relatively simple
Solution Approach 2:
The torque wrench mechanism is designed to self-regulate the torque application through its internal mechanism, automatically controlling the rotation and engagement process without requiring continuous manual adjustment, thereby improving efficiency
3Strength
If electrodes are joined with high torque to ensure secure connection, then joint strength is improved, but thread damage and joint failure risk increase
Solution Approach 1:
The patent changes the torque application approach from high variable torque to controlled consistent torque within a safe range, ensuring sufficient joint strength while preventing thread damage by maintaining torque parameters within optimal limits throughout the joining process
Solution Approach 2:
The torque wrench mechanism provides feedback control by monitoring the torque application and adjusting the rotation accordingly, ensuring that the torque remains within the safe range and preventing over-torquing that could damage the threads
4Reliability
If consistent torque application is implemented, then joint reliability is improved, but the device complexity increases
Solution Approach 1:
The patent implements consistent torque application through a mechanically-controlled torque wrench system that uses mechanical advantage and controlled rotation to maintain uniform torque, achieving reliability without requiring complex electronic control systems
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 apparatus enables safe and efficient joining of electrodes by maintaining consistent torque application and reducing axial stress, preventing joint failure and ensuring precise alignment and secure engagement of electrodes, thus enhancing operational safety and reducing the risk of damage.
Implementation Method 1
Before use, the first and second grip members are disposed in a retracted position. During use, a camming action of the first and second cams causes the first and second grip members to advance radially toward the sides of an electrode
Data Source
AI summary
An electrode lifting apparatus provides a mechanism for lifting a free electrode in a vertical orientation and moving the free electrode suspended below the lifting apparatus to a location for a joining procedure with another electrode or portion of an electrode. The electrode lifting apparatus also supports the free electrode during a joining procedure that includes driven rotation of the free electrode by an electrode torque station. The electrode lifting apparatus includes a bail and a body, the body having a yoke and a housing. First and second arms on the body connect the housing to the yoke. The body may angularly rotate relative to the relatively fixed bail about a reference vertical axis during driven rotation of the free electrode by the torque station. A threaded stem attached to the bail provides a threaded engagement with the yoke allowing such relative angular rotation in some embodiments.