Apparatus for building unburned refractory

TECHNICAL FIELD

The present invention relates to a monolithic refractory depositing system for repairing a molten metal container, such as a ladle used in a steelworks or the like, or constructing a new molten metal container.

BACKGROUND ART

Conventional monolithic refractory depositing methods for repairing a molten metal container, such as a ladle, or constructing a new molten metal container are classified into spraying methods and casting methods.

Repairing methods using spraying are classified into dry spraying methods and wet spraying methods. A dry spraying method conveys refractory powder to a spraying nozzle by the agency of compressed air, mixes water or binder into the refractory powder in the spraying nozzle to produce refractory slurry, and sprays the refractory slurry by the agency of compressed air. A wet spraying method mixes refractory powder and water to produce a refractory mixture, kneads the refractory mixture to produce refractory slurry, sends the refractory slurry through a spraying pipe by a pump, adds a binder to the refractory slurry in a spraying nozzle, and sprays the mixture of the refractory slurry and the binder by the agency of compressed air onto a desired surface.

A casting method, differing from the spraying method, assembles a form at the site, pours refractory slurry prepared by kneading a mixture of water and a refractory material into the form. Although a refractory structure constructed by a casting method has a dense texture and a long life, the construction of such a refractory structure needs a form inevitably.

Recently, there is a trend to use a wet spraying method capable of forming a high-quality refractory structure having durability comparable to that of a refractory structure formed by a casting method, and satisfactory in homogeneity.

The spraying method is carried out by hand spraying work (manual spraying work requiring an operator to hold and operate a nozzle by hand) or mechanical spraying work using a nozzle driving device. When carrying out the spraying method by hand spraying work, the operator needs to move the heavy nozzle by human power, which requires heavy manual work. Furthermore, the spraying method employing hand spraying has drawbacks that the operator working at the site is exposed to injurious rebound loss and dust, and different operators places the material in different thicknesses.

Although dry nozzle driving devices of various types for driving a spray nozzle have been developed for the dry spraying method, any wet nozzle driving device for driving a spray nozzle, suitable for the wet spraying method has not been developed yet.

As mentioned above, the casting method assembles a form at the site, and pours refractory slurry into the form by a belt conveyor or a chute. Recently, a pump capable of forcibly pumping a highly viscous material has been developed. Most recent casting methods convey a material through hoses by force feed to a casting place.

However, the casting method also needs inefficient, heavy manual work to carry a heavy nozzle to the casting place.

Incidentally, the employment of either the spraying method or the casting method is suitable for some repairing work or construction work, and the employment of both the spraying method and the casting methods is suitable for other repair work or construction work. So far, any construction system capable of executing both the spraying method and the casting method has not been developed. Therefore, when construction work needs to carry out both the spraying method and the casting method, both construction apparatuses for carrying out the spraying method and the casting method must be kept at the site and the construction apparatuses must be changed and necessary one of the construction apparatuses must be installed in place. Work for changing the construction apparatuses takes much time, equipment cost increases because a plurality of construction apparatuses are necessary, and increased maintenance work is necessary for the maintenance of the plurality of construction apparatuses.

DISCLOSURE OF THE INVENTION

Accordingly, it is an object of the present invention to provide a monolithic refractory depositing system capable of solving problems in the prior art, of improving working environment, of improving the efficiency of work and of spraying a material so as to form a homogeneous structure in a uniform thickness.

The monolithic refractory depositing system is capable of carrying out both a spraying method and a casting method.

A monolithic refractory depositing system according to the present invention comprises: a carriage placed on rails laid near a molten metal container so as to travel over the molten metal contain along the rails; a truck mounted on the carriage so as to move in directions perpendicular to the moving directions of the carriage; an elevating frame mounted for vertical movement on the elevating frame; a material feed pipe attached to the elevating frame; and a spray nozzle or a pouring pipe to be detachably connected to a lower end of the material feed pipe.

The truck may be a traverse truck mounted on the carriage so as to move in directions perpendicular to the moving directions of the carriage.

The truck may be tiltable relative to the carriage.

A post may be set up on the truck, and the elevating frame may be supported for vertical movement on the post.

A bendable support means capable of moving together with the elevating frame may be connected to a part of the material feed pipe on an upper side of the elevating frame.

The bendable support means may comprise pipes and a rotary joint joining the pipes together for turning relative to each other.

The monolithic refractory depositing system may be provided with a controller for the automatic control of spraying rate at which a material is sprayed, thickness in which the material is to be deposited and a spraying process according to the shape and size of the molten metal container.

The monolithic refractory depositing system may further comprise a support rod capable of turning and vertically moving along the material feed pipe and disposed in a vertical position, and a thickness measuring device held on a lower end part of the support rod to measure the thickness of a part of a structure being formed.

The material feed pipe may be inserted in an upper part of the elevating frame so as to project from a lower part of the elevating frame and supported on the elevating frame.

The monolithic refractory depositing system may be provided with an extendible mechanism, and the extendible mechanism may be attached to an upper part of the truck to move the elevating frame vertically.

The extendible mechanism may be attached to the truck so as to extend downward from an upper part of the truck.

The extendible mechanism may be a linkage of a pantograph type.

The material feed pipe may be connected to a material feed hose for feeding a material.

The material feed hose may be supported on a hose guide.

The pouring pipe may be turnable about a vertical axis.

The monolithic refractory depositing system may further comprise a pouring traverse truck disposed beside the truck and capable of moving in directions perpendicular to the moving directions of the carriage, a second material feed pipe may be connected to an upper part of the pouring traverse truck, and a second pouring pipe may be disposed on a lower part of the pouring traverse truck so as to be turnable in a horizontal plane.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1

is a plan view of a monolithic refractory depositing system in a first embodiment according to the present invention;

FIG. 2

is a sectional elevation taken online L-L in

FIG. 1

;

FIGS. 3A and 3B

are a side elevation and a plan view, respectively, of an elevating frame shown in

FIG. 2

;

FIG. 4

is a sectional view of a spraying nozzle shown in

FIG. 1

;

FIG. 5

is an elevation of a pouring pipe as set on the monolithic refractory depositing system shown in

FIG. 1

;

FIG. 6

is an elevation of a monolithic refractory depositing system in a second embodiment according to the present invention;

FIG. 7

is an elevation of a post shown in

FIG. 6

tilted in a working position;

FIG. 8

is a plan view of a monolithic refractory depositing system in a third embodiment according to the present invention;

FIG. 9

is a sectional elevation taken on line M-M in FIG.

FIG. 10

is a plan view, similar to

FIG. 8

, of the monolithic refractory depositing system in a state different from that shown in

FIG. 8

;

FIG. 11

is an elevation taken on line N—N in

FIG. 10

;

FIG. 12

is a block diagram of assistance in explaining a method of automatically controlling a monolithic refractory depositing system according to the present invention;

FIG. 13

is an elevation of a monolithic refractory depositing system in a fourth embodiment according to the present invention; and

FIG. 14

is an elevation of a monolithic refractory depositing system in a fifth embodiment according to the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Preferred embodiments of the present invention will be described hereinafter with reference to the accompanying drawings.

First, a first embodiment of the present invention will be described.

FIG. 1

is a plan view of a monolithic refractory depositing system in a first embodiment according to the present invention, and

FIG. 2

is a sectional elevation taken online L—L in FIG.

1

. As shown in

FIG. 1

or

2

, right and left rails

2

is laid near the upper end of a pit in which a lade

1

to be repaired is placed.

A gantry-type carriage

4

spanning the ladle

1

and placed on the rails

2

. Wheels

4

a

included in the carriage

4

is driven for rotation by a motor

3

mounted on the carriage

4

to move the carriage

4

along the rails

2

.

The monolithic refractory depositing system in the first embodiment comprises the carriage

4

capable of traveling along rails

2

extended near the ladle

1

, a stationary or movable truck mounted on the carriage

4

, a post set up on the truck, an elevating frame mounted for vertical movement on the post, a material feed pipe inserted in an upper part of the elevating frame to receive a spraying material forced into the material feed pipe by a pump for the force feed of the spraying material, a spray nozzle or a pouring pipe to be detachably connected to a lower end part of the material feed pipe projecting from a lower part of the elevating frame, and a bendable support means capable of vertically moving together with the elevating frame and supported on a part of the material feed pipe on an upper side of the elevating frame. More specifically, the monolithic refractory depositing system comprises the following components designated by reference characters.

A pair of guide rails

5

are fixedly laid on the carriage

4

. A traverse truck

7

is driven for movement along the guide rail

5

in directions perpendicular to the traveling directions of the carriage

4

by an electric cylinder actuator

6

.

A post

8

is set up on the traverse truck. An elevating frame

10

is guided for vertical movement by a vertical guide

11

on one side of the post

8

. The elevating frame

10

is provided with a turning mechanism. A spraying material feed pipe

9

is extended vertically through and supported for rotation on the elevating frame

10

. The spraying material feed pipe

9

is turned about a vertical axis.

A sheave

12

is supported on an upper part of the post

8

. An electric winch

13

is mounted on the traverse truck

7

. A hook

14

connected to an upper part of the elevating frame

10

is connected to the electric winch

13

by a wire

15

extended via the sheave

12

. The elevating frame

10

is moved vertically along the vertical guide

11

through the wire

15

by the electric winch

13

.

Referring to

FIGS. 3A and 3B

showing the material feed pipe

9

in a side elevation and a plan view, respectively, the material feed pipe

9

is supported in a bearing

16

fixed to an upper part of the elevating frame

10

. A sprocket is put on the material feed pipe

9

, and the material feed pipe

9

is driven for rotation through a chain

17

wound round the sprocket by a motor

18

.

A sliding joint

19

is connected to an upper end part of the material feed pipe

9

projecting upward from the upper end of the elevating frame

10

. Another material feed pipe

9

a

has one end connected to one end of the sliding joint

19

by a swivel pipe joint

20

, i.e., a bendable support means, and the other end connected to one end of a third material feed pipe

9

b

by a swivel pipe joint

20

a

. The other end of the material feed pipe

9

b

is connected to a junction box

21

by a swivel pipe joint

20

b

. The junction box

21

is connected to a material supply device

23

by a material feed hose

22

. The swivel pipe joints

20

,

20

a

and

20

b

are bendable support means. The bendable support means enables the material feed pipes

9

a

and

9

b

to move according to the vertical movement of the elevating frame

10

to feed the spraying material smoothly to a spray nozzle

27

.

The bendable support means may comprise rubber joints, flexible joints, bendable joints or bellows pipe joints instead of the swivel pipe joints.

As shown in

FIG. 4

, a curved pipe

24

curved in one direction is joined to the lower end of a material feed pipe

9

c

projecting from the lower end of the elevating frame

10

. A nozzle pipe

25

curved substantially at 90° has an upper end connected to the lower end

24

a

of the curved pipe

24

by a rotary joint

26

. A spray nozzle

27

is connected to the free end of the nozzle pipe

25

. When using a pouring pipe

39

, the upper end of the material feed pipe

9

c

is disconnected from a joint

38

shown in

FIGS. 3A and 3B

, and the pouring pipe

39

is connected to the material feed pipe

9

by the joint

38

as shown in FIG.

5

.

As shown in

FIG. 3B

, a jack

29

is disposed so as to face downward in a lower part of the elevating frame

10

shown in FIG.

3

B swinging motor

28

. the jack

29

is driven by a swinging motor

28

. A rod included in the jack

29

is connected through a rotary joint

30

to a rod

31

. When the jack

29

operates, thread of the jack

29

moves the rod

31

in vertical directions.

An arm

32

is fixed to an upper part of the nozzle pipe

25

as shown in FIG.

4

. The lower end of the rod

31

is connected to the arm

32

. The rod

31

is moved in vertical directions by the swinging motor

28

disposed in the lower part of the elevating frame

10

. The swinging motor

28

drives the jack

29

to make the jack

29

tilt the nozzle pipe

25

through the rod

31

.

An air hose

33

and a binder feed hose

34

are connected to a base part

27

a

of the spray nozzle

27

. As shown in

FIG. 2

, the hoses

33

and

34

are extended through the elevating frame

10

and are connected to a compressed air source

35

and a binder feed pump

36

, respectively.

The operation of the monolithic refractory depositing system in the first embodiment will be described below.

In the following description, it is assumed that the monolithic refractory depositing system is applied to spraying the ladle

1

with a material for repair.

When repairing the ladle

1

by spraying the ladle

1

with a material, the rails

2

are laid near the upper end of the ladle

1

as shown in

FIGS. 1 and 2

. The gantry-type carriage

4

is placed on the rails

2

so as to move in X-directions indicated in FIG.

1

. The level of the carriage

4

is determined so that the movement of the carriage

4

over the ladle

1

may not be obstructed.

The traverse truck

7

, the post

8

and the elevating frame

10

are mounted on the carriage

4

. A power source

37

is connected to the monolithic refractory depositing system, the material feed hose

22

, the air hole

33

and the binder feed hose

34

are connected to corresponding spruces, respectively. The spraying material is conveyed from the material supply device

23

through the material feed hose

22

, the material feed pipes

9

b

,

9

a

and

9

c

to the spray nozzle

27

. At the same time, air is supplied from the compressed air source

35

int the spray nozzle

27

, and a binder is forced into the spray nozzle

27

by the binder feed pump

36

.

Subsequently, a spraying operation is started. The material sprayed on the surface of a bed wall

1

a

of the ladle

1

in an initial stage of the spraying operation, and then the material is sprayed on the surface of a side wall

1

b

of the ladle

1

as shown in FIG.

2

.

When spraying the material on the surface of the bed wall

1

a

, the jack

29

mounted on the elevating frame

10

is operated to direct the spray nozzle

27

downward, and then the electric winch

13

mounted on the elevating frame

10

is operated to adjust the distance between the extremity of the spray nozzle

27

and the surface of the bed wall

1

a

to an appropriate spraying distance.

The spraying distance is dependent on the construction of the spray nozzle. Usually, the spraying distance is in the range of about 200 to 800 mm. If the spraying distance does not match with the construction of the spray nozzle, the bed wall

1

a

will irregularly be filled or the bed wall

1

a

will not be finished in a smooth, flat surface, and hence the spraying operation will not satisfactorily be achieved.

During the spraying operation, the motor

3

drives the carriage

4

for longitudinal reciprocating movement in the X-directions, and the electric cylinder actuator

6

drives the traverse truck

7

for transverse reciprocating movement in Y-directions to spray the material over the entire surface of the bed wall

1

a.

After the spraying operation for the bed wall

1

a

has been completed, the jack

29

is operated to direct the spray nozzle

27

toward the side wall

1

b

. The distance between the spray nozzle

27

and the surface of the side wall

1

b

is adjusted properly by moving the traverse truck

7

in the Y-directions. Then, the carriage

4

is moved while the elevating frame

10

is moved vertically to spray the surface of the side wall

1

b

with the spraying material.

The jack

29

is operated to direct the spray nozzle

27

sequentially toward a side wall

1

c

opposite the side wall

1

b

, and the side walls extending between the side walls

1

b

and

1

c

to spray the surfaces of all the side walls.

The operation of the monolithic refractory depositing system when the monolithic refractory depositing system is applied to repair the ladle

1

by pouring a casting material.

The rod

31

shown in

FIG. 3A

is removed, the material feed pipe

9

c

shown in

FIG. 3A

is disconnected from the joint

38

, and the pouring pipe

39

is connected to the joint

38

as shown in FIG.

5

.

The position of the elevating frame

10

is adjusted so as to corresponding substantially to the center of the ladle

1

by moving the carriage

4

in the X-directions by the motor

3

and moving the traverse truck

7

in the Y-directions (

FIG. 1

) by the electric cylinder actuator

6

. The discharge opening

39

a

of the pouring pipe

39

is disposed opposite to a space

41

formed between a core

40

placed in the ladle

1

and the circumferential wall of the ladle

1

. If the space

41

between the ladle

1

and the core

1

is round, the pouring pipe

39

is turned while the casting material is discharged through the discharge opening

39

a

into the space

41

. If the space

41

between the ladle

1

and the core

40

is not round, the discharge opening

39

a

is located over the space

41

and the casting material

42

is discharged into the space

41

while the carriage

4

is moved in the x-directions by the motor

3

and the traverse truck

7

is moved in the Y-directions (

FIG. 1

) by the electric cylinder actuator

6

.

The respective traveling speeds of the carriage

4

and the traverse truck

7

, the moving speed of the elevating frame

10

, the speed of turning of the material feed pipe

9

about a vertical axis, and the speed of swing motion of the spray nozzle

27

can be controlled according to spraying conditions by the inverter control of the drive motors.

The operation of the monolithic refractory depositing system may be controlled by an operator staying on the carriage

4

or by operating a remote control pendant switch device

43

(

FIGS. 2 and 5

) or a radio controller by an operator staying at a position suitable for visually monitoring spraying conditions.

A monolithic refractory depositing system in a second embodiment according to the present invention will be described hereinafter.

FIG. 6

is an elevation of the monolithic refractory depositing system in the second embodiment and

FIG. 7

is an elevation showing the monolithic refractory depositing system in a tilted position during operation. The second embodiment shown in

FIGS. 6 and 7

differs from the first embodiment shown in

FIGS. 1 and 2

in that the second embodiment has a tiltable truck

45

instead of the traverse truck

7

employed in the first embodiment. Since most parts of the second embodiment excluding those around the tiltable truck

45

are similar to the corresponding parts of the first embodiment shown in

FIGS. 1 and 2

. Therefore parts shown in

FIGS. 6 and 7

like or corresponding to those shown in

FIGS. 1 and 2

are designated by the same reference characters and the description thereof will be omitted and only the parts different from those of the first embodiment will be described.

As shown in

FIG. 6

, the tiltable truck

45

is pivotally joined with a pin to a bearing

4

b

held on a carriage

4

so as to be tiltable in the traveling directions of the carriage

4

.

A post

8

′ is set upright on the tiltable truck

45

and is pivotally joined with a pin to a bearing

4

c

fixed to the upper surface of the tiltable truck

45

so as to be tiltable in directions perpendicular to the traveling directions of the carriage

4

. An electric cylinder actuator

47

Y has a base end part pivotally joined with a pin to a bearing

46

fixed to the upper surface of the tiltable truck

45

. The free end of a rod included in the electric cylinder actuator

47

Y is pivotally joined with a pin to a bearing

8

′

a

fixed to a middle part of the post

8

′.

The rod of the electric cylinder actuator

47

Y is stretched out to tilt the post

8

′ in a direction perpendicular to the traveling directions of the carriage

4

. the rod of another electric cylinder actuator

47

X, not shown, disposed on the carriage

4

is stretched out to tilt the post

8

′ in a direction parallel to the traveling directions of the carriage

4

.

Thus, the post silted in the X- and the Y-directions (FIG.

1

), a spray nozzle or the pouring pipe

39

can be moved, similarly to the spray nozzle

27

and the pouring pipe

39

shown in

FIGS. 1 and 5

, in directions parallel to the X- and the Y-directions.

FIG. 7

shows the post

8

′ tilted in a desired direction to move the spray nozzle

27

to a desired spraying position.

A monolithic refractory structure constructing system in a third embodiment according to the present invention will be described hereinafter.

FIG. 8

is a plan view of the monolithic refractory structure constructing system in the third embodiment and

FIG. 9

is a sectional view taken on line M—M in FIG.

8

.

The third embodiment is provided, in addition to the components of the monolithic refractory structure constructing system shown in

FIG. 1

,

2

or

5

, with a pouring traverse truck

50

. Only the additional components of the third embodiment not included in the monolithic refractory structure constructing system shown in

FIGS. 1

,

2

and

5

will be described to avoid duplication.

Referring to

FIG. 8

, a traverse truck

7

is mounted on a carriage

4

for movement in Y-directions perpendicular to X-directions, i.e., the moving directions of the carriage

4

, and the pouring traverse truck

50

is mounted on the carriage

4

for movement in parallel to the moving directions of the traverse truck

7

.

FIG. 11

is a sectional view taken on line N—N in

FIG. 8

, in which the pouring traverse truck

50

in a refractory material pouring operation is shown in an elevation.

Rails

51

are laid on the carriage

4

in parallel to guide rails

5

for guiding the traverse truck

7

, and the pouring traverse truck

50

is moved along the rails

51

by an electric cylinder actuator

52

.

Referring to

FIG. 11

, a casing

54

is mounted on the pouring traverse truck

50

, and a second material feed pipe

53

is extended through and supported for turning on the casing

54

. The second material feed pipe

53

, and the material feed pipes

9

,

9

a

and

9

b

are used for separate purposes, respectively. A motor

55

for driving the second material feed pipe

53

for turning is mounted on the pouring traverse truck

50

. A gear

57

mounted on the material feed pipe

53

and a pinion

56

mounted on the output shaft of the motor

55

are engaged to drive the second material feed pipe

53

for turning about a vertical axis.

A 90° elbow

58

has one end connected through a sliding joint

59

to an upper part of the casing

54

, and the other end connected to a material feed hose

22

connected to a material supply device

23

.

A second pouring pipe

49

is fixedly joined to the lower end of a part of the second material feed pipe

53

projecting downward from the casing

54

by a joint

48

.

Repairing operation for repairing a ladle

1

by using a casting material will be described below.

Referring to

FIGS. 10 and 11

, rails

2

are laid near the upper end of the ladle

1

, the gantry-type carriage

4

is placed on the rails

2

so as to span the ladle

1

, and the pouring traverse truck

50

is mounted on the carriage

4

so as to move in directions perpendicular to the traveling directions of the carriage

4

.

The elbow

58

is connected through the sliding joint

59

to the upper part of the casing

54

mounted on the pouring traverse truck

50

, and the elbow

58

is connected to the material supply device

23

by the material feed hose

22

.

The second pouring pipe

49

is fixedly joined to the lower end of a part of the second material feed pipe

53

projecting downward from the casing

54

by a joint

48

.

The carriage

4

is moved over the ladle

1

by a motor

3

to locate the same at a position corresponding to the center of the ladle

1

. Then, the pouring traverse truck

50

is moved in a transverse direction by the electric cylinder actuator

52

to locate the casing

54

at a position substantially corresponding to the center of the ladle

1

to locate the discharge opening

49

a

of the second pouring pipe

49

opposite to a space formed between the circumferential wall of the ladle

1

and a core

40

placed i the ladle

1

.

After a predetermined quantity of the casting material

42

has been poured into the space

41

, the carriage

4

and the pouring traverse truck

50

move the second pouring pipe

49

to the next pouring position. The motor

55

is actuated to drive the second material feed pipe

53

for turning through the pinion

56

of the motor

55

, the gear

57

engaged with the pinion

56

and mounted on the second material feed pipe

53

so that the discharge opening

49

a

of the second pouring pipe

49

is moved to the next pouring position. Then, a predetermined quantity of the casting material is poured into the space

41

. This cycle of operation is repeated to fill up the space

41

between the ladle

1

and the core

40

with the casting material.

If the space

41

formed between the ladle

1

and the core

40

is round, the second pouring pipe

49

is formed in a length equal to half the diameter of the round space

41

, the positions of the carriage

4

and the pouring traverse truck

50

are adjusted so as to locate the casing

54

fixedly at a position above the ladle

1

and corresponding to the center of the ladle

1

, and then the second material feed pipe

58

is turned to fill up the space

41

between the ladle

1

and the core

40

with the casting material

42

.

The third embodiment additionally provided with the casting traverse truck

50

, the second material feed pipe

53

only for casting and the second pouring pipe

49

exercises the following effects.

Different pouring materials can be used by using the pouring pipe

39

connected to the joint

38

as shown in

FIG. 5

, and the second pouring pipe

49

. Therefore, the third embodiment is able to repair parts requiring different kinds of repair work properly by pouring the different casting materials selectively to those parts. When the material feed pipe

9

c

connected to the spray nozzle

27

is connected to the joint

38

as shown in

FIG. 9

, spraying work can be performed by using the spray nozzle

27

immediately after completing repairing work for repairing parts requiring repair by casting the material by the second pouring pipe

49

.

A monolithic refractory structure constructing system in a fourth embodiment according to the present invention will be described hereinafter.

FIG. 13

shows an elevating mechanism for vertically moving the elevating frame

10

. When the elevating frame

10

is moved vertically along the post

8

set up on the traverse truck

7

as mentioned in the description of the foregoing embodiments, the overall height of the monolithic refractory structure constructing system is inevitably great and the traverse truck

7

supporting the post

8

must be large, which affects adversely to the cost and the installation space required by the monolithic refractory structure constructing system and, since the material feed pipe

9

is long, the material feed pipe

9

requires difficult work for replacing the same with another one when the same is clogged with the material. The fourth embodiment is designed, in view of those problems, to construct a monolithic refractory structure constructing system in a reduced height, to use a small traverse truck and to reduce the length of the material feed pipe

9

.

The monolithic refractory structure constructing system in the fourth embodiment is provided with a frame truck

61

having the shape of a vertically elongate, rectangular frame and serving as a traverse truck. A elevating frame

10

is suspended from the frame truck

61

by an extendible mechanism

62

so as to be moved vertically. A pantograph type linkage

62

a

is used as the extendible mechanism

62

. The pantograph type linkage

62

a

is formed by pivotally joining a plurality of unit sections each formed by pivotally joining together the respective middle parts of two links. The upper end of the pantograph type linkage

62

a

is connected to an upper frame

61

a

of the frame truck

61

. A base plate

63

is attached to the lower end of the pantograph type linkage

62

a

. An elevating frame

10

similar to that employed in the foregoing embodiments is held by a holding member

64

fixedly attached to the lower surface of the base plate

63

. A material feed pipe

9

has an upper end connected so as to be turnable to the elevating frame

10

.

A winch

65

for hoisting is mounted on the upper frame

61

a

of the frame truck

61

. The lower end of a wire

66

child on a drum included in the winch

65

is attached to the base plate

63

. The winch

65

winds and unwinds the cable to elevate and lower the base plate

63

holding the elevating frame

10

so as to contract and extend the pantograph type linkage

62

a.

A material feed hose

22

has one end connected to the upper end of the material feed pipe

9

and the other end connected to a material supply device

23

. The material feed hose

22

is supported on an upward convex hose guide

68

supported on a post

67

set up on the carriage

4

. An air hose

33

and a binder feed holes

34

extended from corresponding supply devices via the hose guide

68

to the elevating frame

10

.

The monolithic refractory depositing system in the fourth embodiment is similar in other respects to the monolithic refractory depositing systems in the foregoing embodiments. Components of the monolithic refractory depositing system in the fourth embodiment like or corresponding to those of the monolithic refractory depositing systems in the foregoing embodiments are designated and the description thereof will be omitted.

In the fourth embodiment, the material feed pipe

9

may be very short because the elevating frame

10

is moved vertically under the carriage

4

. Consequently, the possibility of the material feed pipe

9

being clogged with the material is reduced and, even if the material feed pipe

9

should be clogged with the material, the material feed pipe

9

can easily be replaced with another one. In the fourth embodiment, any post need not be set up on the traverse truck, and the monolithic refractory depositing system can be formed in a compact structure not requiring a large space for installation.

The nozzle can properly be positioned by operating the winch

65

during a spraying or casting operation.

A monolithic refractory depositing system in a fifth embodiment according to the present invention will be described with reference to FIG.

14

.

The monolithic refractory depositing system shown in

FIG. 14

is capable of depositing a material exactly in a desired thickness for repair by spraying so that a lining may not be formed in an insufficient thickness and an excessive amount of the material may not be deposited by spraying.

Basically, the monolithic refractory depositing system shown in

FIG. 14

is similar in construction to that previously described with reference to

FIGS. 1

to

4

. In

FIG. 14

, some components are omitted. As shown in

FIG. 14

, a rotating mechanism

70

provided with a support pipe

71

is mounted on an elevating frame

10

, and a thickness measuring device

72

is attached to the lower end of the support pipe

71

.

The turning mechanism

70

is similar to the turning mechanism for turning the material feed pipe

9

. A chain

74

is extended between a sprocket mounted on the output shaft of a motor

73

and a sprocket mounted on a support pipe

71

, and the motor

73

drives the support pipe

71

for turning through an angle of 360°. The thickness measuring device

72

can vertically be moved by an elevating mechanism, not shown, to a level below that of the level of a spray nozzle

27

to enable the thickness measuring device

72

to execute measurement without being obstructed by the spray nozzle

27

.

The thickness measuring device

72

is a laser thickness meter or an ultrasonic thickness meter commercially available from, for example, Kabushiki Kaisha Kiiensu. Data on the profile of a lining is given previously to an arithmetic unit, the difference between the actual thickness of the lining and the from a desired thickness is calculated on the basis of a measured distance and a position data provided by an NC device, and measured results are displayed.

When repairing the lining, A part to be repaired can be finished in a predetermined thickness by controlling the moving speed of the spray nozzle

27

by the NC device if the thickness of the part to be repaired is measured before starting a spraying operation.

The monolithic refractory depositing system shown in

FIG. 14

is similar in other respects as the monolithic refractory depositing system shown in FIG.

2

. In

FIG. 14

components like or corresponding to those of the monolithic refractory depositing system shown in

FIG. 2

are designated by the same reference characters and the description thereof will be omitted.

The fifth embodiment is capable of depositing a material exactly in a desired thickness by spraying so that the lining may not be formed in an insufficient thickness and an excessive amount of the material may not be deposited, which prevents troubles during operation and reduces the costs.

A method of automatically controlling a monolithic refractory depositing system according to the present invention will be described below.

FIG. 12

is a block diagram of assistance in explaining a method of automatically controlling a monolithic refractory depositing system according to the present invention. The material supply rate of a material supply device

23

and the moving speed of a spray nozzle are controlled in an automatic control mode to finish a part of a lining to be repaired in a fixed thickness (usually, a thickness on the order of 200 mm). A program representing a pattern specifying nozzle moving speed and moving order is loaded into a controller

60

before starring a spraying operation. In most cases, the material supply device

23

is provided with a piston pump. It is difficult to control the material supply device

23

so that the flow of the material may not be pulsated due to the pulsative characteristic of the piston pump.

Instantaneous material discharge rate is measured by a measuring device, such as a reed switch combined with a piston, or an ultrasonic flow meter or an electromagnetic flow meter combined with a material feed pipe. The movement of a material feed pipe in X, Y and Z directions, the turning of the material feed pipe about a vertical axis, and the angle of a spray nozzle are regulated automatically according to a measured instantaneous discharge rate. Servomotors capable of accurate position determination and speed regulation are used as driving means for automatic regulation.

Although not shown in

FIG. 12

, a flow meter for measuring the amount of the material pumped by a spraying material pump and a detector for detecting an additive are electrically connected to the controller

60

for measuring material feed rate. As mentioned above, the program representing a pattern specifying nozzle moving speed and moving order is loaded into the controller

60

. A carriage

4

is driven for movement by a motor

3

or a post

8

is driven for tilting by an electric cylinder actuator

47

X to move the spray nozzle in the X-direction. A transverse truck

7

is driven for transverse movement by an electric cylinder actuator

6

or a post

8

′ is driven for tilting by an electric cylinder actuator

47

Y disposed with its axis extended perpendicularly to that of the electric cylinder actuator

47

X to move the spray nozzle in the Y-direction. An elevating frame

10

is moved vertically by the electric winch

13

to move the spray nozzle in the Z-direction.

A material feed pipe

9

c

is turned about its vertical axis by a motor

18

. The spraying angle of the spray nozzle

27

is adjusted by driving the spray nozzle

27

for turning by a swinging motor

28

.

As is apparent from the foregoing description, the present invention has the following effects.

1) When repairing a molten metal container, such as a ladle, the spray nozzle attached to the heavy pipe need not be held by hand, and the spray nozzle can be driven for traveling, transverse movement, vertical movement and turning by the devices to spray all the surfaces of the molten metal container with a material at proper spraying angles. Thus, stable spraying work can be achieved by only one operator and labor cost can be reduced.

2) The monolithic refractory depositing system can selectively be used for spraying work or casting work by selectively using a spraying pipe or a pouring pipe, work for changing the construction apparatuses according to the required work is not necessary and, therefore, the efficiency of work can greatly be improved. Since only one system is necessary, equipment cost is reduced and space for installation can be reduced.

3) Since the spray nozzle can be driven for traveling, transverse movement, vertical movement and turning by the devices to spray all the surfaces of the molten metal container with a material at proper spraying angles, the facility of work is improved.

4) Since the construction apparatus is provided with both the mechanisms for spraying and casting, the spraying pipe and the pouring pipe need not be replaced with each other, so that the efficiency of work is further improved.

5) Since the swivel pipe joints are employed as the bendable support means, the spraying material is able to flow smoothly through the material feed pipes even if the material feed pipes are moved vertically as the elevating frame is moved.

6) The spraying work can automatically be controlled, and the construction apparatus can be controlled in a remote control mode from a position apart from the site and hence the operator is freed from heavy manual work.

7) Since the material feed pipe

9

is very short because the elevating frame

10

is moved under the carriage

4

, the possibility of the material feed pipe

9

being clogged with the material is reduced and, even if the material feed pipe

9

should be clogged with the material, the material feed pipe

9

can easily be replaced with another one. Since any post need not be set up on the traverse truck, the monolithic refractory depositing system can be formed in a compact structure and the traverse truck may be small and the monolithic refractory depositing system needs a small space for installation.

8) Since the thickness measuring device

72

is attached to the lower end of the support pipe

71

, the material can be deposited exactly in a desired thickness by spraying so that the lining may not be formed in an insufficient thickness and an excessive amount of the material may not be deposited, which prevents troubles during operation and reduces the costs.

Number	Date	Country
S52-7818	Jan 1977	JP
S59-70461	Apr 1984	JP
S63-154258	Jun 1988	JP
H1-31340 U	Sep 1989	JP
H4-7176 U	Feb 1992	JP
6-145742	May 1994	JP
H6-48139	Jun 1994	JP
H6-69697 U	Sep 1994	JP
H8-25023	Jan 1996	JP
8-188809	Jul 1996	JP

Apparatus for building unburned refractory

Information

Patent Number

Date Filed

Date Issued

Inventors

Original Assignees

Examiners

Agents

CPC

US Classifications

Field of Search

US

International Classifications

Abstract

Description

Claims

Priority Claims (1)

PCT Information

Foreign Referenced Citations (10)