Wireless Magnet Sensor for Ladle Lifting Alignment
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Solution Overview
Problem
Existing lifting systems in metallurgical plants, particularly in the BOF process, face alignment issues due to harsh conditions and complexity in detection systems, leading to potential accidents from misalignment.
Innovation Solution
A detection system comprising a magnet, sensor unit, and transmitter unit aligned for correct alignment of crane hooks and ladle trunnions, using a wireless communication method to provide a simple and robust alignment confirmation without complex wired connections, capable of withstanding elevated temperatures and dusty environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnetic flux detection device with multiple components is used to detect alignment, then detection capability is improved, but device complexity increases and wired connections are required
Solution Approach 1:
The patent replaces complex wired magnetic flux detection systems with a wireless communication system. A magnet is attached to the ladle and a sensor unit in the crane hook detects its position wirelessly, eliminating the need for complex wired connections and reducing system complexity while maintaining detection capability.
Solution Approach 2:
The patent extracts the essential function of alignment detection by using only a magnet and sensor unit, removing unnecessary components from complex prior art systems. This extraction maintains the core detection capability while significantly simplifying the overall system architecture.
2Reliability
If wired connections are used between the object and crane for detection, then signal transmission is reliable, but installation complexity and robustness in harsh environments deteriorate
Solution Approach 1:
The patent substitutes wired mechanical connections with wireless communication technology. The sensor unit communicates alignment information wirelessly to the crane control system, eliminating installation complexity associated with wired connections while maintaining signal transmission reliability through wireless protocols.
3Measurement precision
If complex detection systems are used to ensure alignment, then detection accuracy is improved, but robustness in harsh environmental conditions deteriorates
Solution Approach 1:
The patent replaces complex electronic detection systems with a simple magnet-sensor wireless system. This substitution improves robustness by eliminating vulnerable wired connections and complex electronics, while maintaining detection accuracy through precise magnetic field sensing that can operate reliably in harsh metallurgical plant 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
Ensures accurate and safe lifting operations by providing real-time alignment feedback to the crane control system, reducing human error and enhancing safety by automatically disabling hoisting in unsafe situations.
Implementation Method 1
the sensor unit will detect a change in the magnetic field due to the correct alignment of the object and the lifting device
Data Source
AI summary
A lifting system for a metallurgical plant including an object with one or more trunnions and a lifting device with one or more lifting hooks for receiving the trunnions, wherein the lifting system further includes a detection system, the detection system includes a receiver, a sensor, a magnet and a transmitter, and wherein the magnet and the sensor are aligned upon correct alignment of at least one lifting hook and one trunnion such that a signal is submitted to the receiver.