Characterization of refractory lining of metallurgical vessels using autonomous scanners

• US 10,175,040 B2
• Filed: 03/20/2015
• Issued: 01/08/2019
• Est. Priority Date: 03/20/2015
• Status: Active Grant

• Current Assignee: Process Metrix, LLC (Vesuvius Plc)
• Original Assignee: Process Metrix, LLC (Vesuvius Plc)
• Inventors: Bonin, Michel Pierre, Hoog, Jared Hubert
• Primary Examiner(s): Ratcliffe, Luke D
• Application Number:
  US14/663,726
• Publication Number:
  US 20160273907A1
• Time in Patent Office: 1,390 Days
• CPC Class Codes: F27D 21/0021 Devices for monitoring linings for wear
• CPC Class Codes: G01B 11/026 by measuring distance between sensor and object G01B11/0608 takes precedence
• CPC Class Codes: G01B 11/0616 of coating
• CPC Class Codes: G01B 11/30 for measuring roughness or irregularity of surfaces
• CPC Class Codes: G01S 17/10 using transmission of interrupted, pulse-modulated waves determination of distance by phase measurements G01S17/32
• CPC Class Codes: G01S 17/42 Simultaneous measurement of distance and other co-ordinates indirect measurement G01S17/46
• CPC Class Codes: G01S 17/48 Active triangulation systems, i.e. using the transmission and reflection of electromagnetic waves other than radio waves
• CPC Class Codes: G01S 17/88 Lidar systems specially adapted for specific applications
• CPC Class Codes: G01S 17/89 for mapping or imaging
• CPC Class Codes: G01S 7/4808 Evaluating distance, position or velocity data
• CPC Class Codes: Y02P 10/20 Recycling
• CPC Class Codes: Y10S 901/01 Mobile robot

Abstract

Apparatuses, methods, and systems are disclosed for autonomously characterizing the refractory lining in a container using an scanner that includes a scanning laser range finding system, a control system being communicatively connected to the laser scanning system to control the scanner; and a robotic vehicle having a controller communicatively connected to the control system and a drive system to propel the scanner autonomously in an area adjacent to the container, wherein characterization of the refractory lining is performed by comparing refractory thickness values determined from the distances measured from the laser scanning system to the surface of the refractory lining and the relative position of the scanner and the container, and comparing the same to a reference measurement of the refractory lining.

Claims

1. A scanner for characterizing a refractory lining in a container, the scanner comprising:

a frame;

a laser scanning system mounted on the frame, said laser scanning system having a laser, a scanner, optics, a photodetector, and receiver electronics, said laser scanning system being configured to measure, in measurement position, distances from the laser scanning system to a plurality of points on a surface of the refractory lining;

a robotic vehicle attached to the frame, said robotic vehicle having drive system comprising wheels or tracks and a controller configured to operate the drive system and control motion of said robotic vehicle, said robotic vehicle being configured for motion on a floor to propel the scanner autonomously in an area adjacent to the container from a first position to a second position along the floor, and said robotic vehicle not comprising gunning equipment;

a tracking system, in communicative connection with the controller, configured to determine the position and orientation of the scanning system relative to the alignment of the container, to provide range data measured in the frame of reference of the tracking system and converted to a frame of reference relative to the container, and to provide position feedback to the drive system of the robotic vehicle; and

a control system comprising hardware and software to control the scanner, said control system being communicatively connected to said laser scanning system, said controller, and said drive system, wherein the refractory lining is characterized by comparing the plurality of distances measured by the laser scanning system to a reference surface of the refractory lining.

2. The scanner according to claim 1, wherein a first measurement with the laser scanner system is performed with the scanner located at the second position and the scanner is positioned at the first position by a user.

3. The scanner according to claim 1, wherein a first measurement with the laser scanner is performed with the scanner located at the first position and the container is moved before a second measurement with the laser scanner is performed.

4. The scanner according to claim 3, wherein the container is moved by a command from the control system.

5. The scanner according to claim 1, further comprising:

a range finder mounted on the frame and communicatively connected to said control system, said range finder being configured to measure distances between the scanner and one or more objects in a surrounding of the scanner.

6. The scanner according to claim 1, wherein the control system is located in a location separate from the location of the scanner.

7. The scanner according to claim 1, the robotic vehicle further comprising:

an electrical source to provide power to the drive system.

8. The scanner according to claim 1, further comprising:

a hydrocarbon source of energy disposed on the frame; and

an electrical generator powered by the hydrocarbon source of energy, the electrical generator being configured to provide power to the drive system.

9. The scanner according to claim 5, where said range finder is configured to measure a position of the autonomous scanner relative to a position of the container using a rotating laser beacon and each positional angle between the rotating laser beacon and at least three reflectors placed in the surrounding.

10. The scanner according to claim 9, wherein the characterization of the refractory lining is accomplished by converting the plurality of distances from a frame of reference of the range finder to a frame of reference of the container, said conversion being based at least in part on a position of the scanner relative to a position of the container.

11. The scanner according to claim 5, wherein said range finder is configured to measure a position of the scanner relative to a position of the container using targets placed on a bottom of the container.

12. The scanner according to claim 5, wherein said control system is configured to avoid obstacles in a path of the scanner using range measurements made by the range finder.

13. A method for characterizing a refractory lining in a container, the method comprising:

propelling a laser scanning system mounted on a frame autonomously in an area adjacent to the container from a first position to a second position along a floor by the use of a robotic vehicle attached to the frame, said robotic vehicle having a drive system comprising wheels or tracks configured for motion on the floor and a controller configured to operate the drive system and control motion of said robotic vehicle; and

said robotic vehicle not comprising gunning equipment;

tracking the position of the laser scanning system with a tracking system configured to determine the position and orientation of the scanning system relative to the alignment of the container, to obtain range data measured in the frame of reference of the tracking system and converted to a frame of reference relative to the container, and to provide position feedback to the drive system of the robotic vehicle;

measuring, with the laser scanning system in measurement position, distances from the laser scanning system to a plurality of points on a surface of the refractory lining, said laser scanning system having a laser, a scanner, optics, a photodetector, and receiver electronics;

controlling the scanner by use of a control system comprising hardware and software, said control system being communicatively connected to said laser scanning system, said controller, and said drive system; and

characterizing the refractory lining by comparing the plurality of distances measured by the laser scanning system to a reference surface of the refractory lining.

14. The method according to claim 13, wherein the measuring with the laser scanner system is performed with the scanner located at the second position and the scanner is positioned at the first position by a user.

15. The method according to claim 13, wherein the measuring with the laser scanner is performed with the scanner located at the first position, the method further comprising:

moving the container before a second measurement with the laser scanner is performed.

16. The method according to claim 13, further comprising:

measuring distances between the laser scanning system and one or more objects in a surrounding of the laser scanner system by use of a range finder mounted on the frame.

17. The method according to claim 13, wherein the controlling takes place from a location separate from a location of the scanner.

18. The method according to claim 16, wherein said range finder is configured to measure a position of the autonomous scanner relative to a position of the container using a rotating laser beacon and each positional angle between the rotating laser beacon and at least three reflectors placed in the surrounding.

19. The method according to claim 18, wherein a characterization of the refractory lining is accomplished by converting the plurality of distances from a frame of reference of the range finder to a frame of reference of the container, said conversion being based at least in part on a position of the scanner relative to a position of the container.

20. The method according to claim 16, wherein said control system is configured to avoid obstacles in a path of the scanner using range instruments made by the range finder.