Optical Waveguide Ladle Wall for Continuous Stress Monitoring
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Solution Overview
Problem
Current metallurgical ladles and intermediate containers lack effective and cost-efficient methods for precise monitoring of mechanical and thermal loads on their walls, with existing solutions limited to selective point measurements and lacking continuous monitoring capabilities.
Innovation Solution
Integration of optical waveguides within the walls of the ladle or intermediate container, arranged between refractory and metal layers, allowing for direct material contact and enabling continuous temperature and mechanical stress monitoring through evaluation units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If individual measuring probes are used for temperature and stress monitoring, then measurement capability is provided at selected points, but measurement precision and coverage are limited to discrete locations only
Solution Approach 1:
The optical waveguide is divided into multiple sensing sections along its length, with each section capable of independent measurement. This segmentation allows continuous monitoring along the entire wall surface rather than at discrete points, while the modular nature of the segmented waveguide keeps the system manageable and installable in sections.
Solution Approach 2:
The monitoring capability transitions from zero-dimensional point measurements using individual probes to one-dimensional continuous measurements along the waveguide path embedded in the wall. This dimensional transition enables comprehensive surface monitoring without proportionally increasing system complexity.
2Measurement precision
If optical waveguides are integrated into the wall with direct material contact for strain measurement, then measurement precision improves, but installation complexity and manufacturing difficulty increase
Solution Approach 1:
Holes or channels for waveguide installation are pre-formed in the refractory lining during the manufacturing or construction phase. This preliminary action simplifies the subsequent waveguide installation by providing ready-made pathways, eliminating the need for complex drilling or embedding operations after the lining is in place.
Solution Approach 2:
The refractory lining itself serves as an intermediary medium that facilitates waveguide installation. By embedding the waveguide within the lining structure during manufacturing, the lining acts as a protective conduit and installation medium, simplifying the overall manufacturing process while ensuring proper waveguide positioning and material contact.
3Ease of manufacture
If optical waveguides are laid loosely in bore holes for temperature measurement, then installation ease improves, but measurement reliability for mechanical load decreases
Solution Approach 1:
The waveguide installation employs different local conditions along its path: in sections where temperature measurement is required, the waveguide is laid loosely in bore holes for easy installation and thermal contact; in sections where strain measurement is required, the waveguide is firmly clamped or bonded to ensure mechanical contact. This local differentiation of installation quality enables both measurement types with appropriate reliability.
4Measurement precision
If multiple measuring elements are integrated throughout the wall structure, then monitoring precision and coverage improve, but device complexity and cost increase
Solution Approach 1:
The optical waveguide is designed as a multi-functional sensing element that simultaneously performs both temperature measurement (through thermal expansion effects) and strain measurement (through mechanical deformation). This universality allows a single integrated structure to replace multiple separate measurement systems, reducing overall device complexity while maintaining comprehensive monitoring precision.
Solution Approach 2:
The patent combines temperature sensing and strain sensing capabilities into a single optical waveguide structure embedded in the wall. By merging these two measurement functions into one integrated element rather than using separate probe systems, the overall device complexity is reduced while achieving continuous multi-parameter monitoring throughout the wall structure.
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
Enables precise and cost-effective monitoring of thermal and mechanical stresses across the surface of the container, facilitating the assessment of wear and operational conditions, with robust signal transmission and high reliability under harsh conditions.
Implementation Method 1
the optical waveguide can also be used lying loosely in a bore or a cladding tube for the purpose of measuring the temperature due to thermal expansion of the optical waveguide
Implementation Method 2
For strain measurement or for determining the mechanical load on a component, the optical waveguide must be firmly installed/clamped in a material
Data Source
Figure 1~2
AI summary
The invention relates to a foundry ladle or an intermediate vessel (1) for receiving a liquid metal for further processing of said liquid metal, wherein at least a part of the wall (2) of the foundry ladle or of the intermediate vessel (1) comprises at least one measuring element (3) for detecting the temperature and/or the mechanical load. In order to be able to detect the temperatures and/or the mechanical load in the wall of the foundry ladle or in the intermediate vessel precisely, quickly and along the extension of the wall, according to the invention the measuring element (3) comprises at least one optical waveguide which is integrated in the wall (2) of the foundry ladle or of the intermediate vessel (1).