Description:FIELD OF INVENTION
[0001] Embodiments of the present disclosure relate to the field of measurement systems, and more particularly, a system and a method for contactless height measurement of a refractory checker.
BACKGROUND
[0002] Refractory checkers are refractory products used in both recuperative and regenerative furnaces, serving as a medium for heat transfer to convert cold air into hot air through convective heat exchange. The number of checkers required for each furnace can vary significantly, ranging from 100,000 to 300,000 pieces, depending on the design and size of a hot blast stove.
[0003] The refractory checkers are manufactured by various manufacturers and are differentiated by height, which is also indicated by different colors. Typically, the hot blast stove may reach heights up to 40 meters, with each checker having an average height of 150 mm (and each color band will start from 147mm and reach up to 152 mm, these heights are divided on to various color bands with 1 mm difference in height). Maintaining precise dimensions is crucial here; a variation of just 0.05 mm in a single layer may lead to significant dimensional discrepancies over the height of a 40-meter hot blast stove, potentially comprising between 100 and 200 layers. Furthermore, the internal holes in each checker are interconnected, necessitating clear pathways from top to bottom. If not aligned properly, the layers may not sit correctly. Therefore, it's essential to maintain a height tolerance of ±0.5 mm for each checker.
[0004] Several methods are available for measuring the height of the refractory checker. One method is to use a measuring tape, though detecting a 0.5 mm difference is challenging with the measuring tape. Color-coded gauges are the other method but this conforming to Indian standards. Further the most accurate measuring tool is a Vernier caliper.
[0005] However, identifying the correct color for each checker with the available method is complicated by the presence of 12 ribs on each unit. Measuring the height of the ribs across potentially thousands of pcs through the mentioned method is taking substantial time, and a skill is required to understand the differential dimensions, which in-turn reduces the yield.
[0006] Hence, there is a need for an improved system and a method for contactless height measurement of a refractory checker which addresses the aforementioned issue(s).
OBJECTIVES OF THE INVENTION
[0007] The primary objective of the invention is to measure the height of refractory checkers accurately using a laser and without any physical contact.
[0008] Another objective of the invention is to automate height measurement process by placing the checker on a rotating base plate and utilizing sensors to identify the home position, along with a servo motor to control the speed and angle of rotation, thereby reducing the human error.
[0009] Yet another objective of the invention is to capture data via a Universal Serial Bus (USB) device that allows for the easy transfer and analysis of collected data.
BRIEF DESCRIPTION
[0010] In accordance with an embodiment of the present disclosure, a system for contactless height measurement of a refractory checker is provided. The system includes a control panel equipped with a power switch. The power switch is adapted to allow a user to activate the system. The system includes a rotating base plate operatively coupled to the control panel. The rotating base plate is adapted to hold the refractory checker for height measurement. The system includes a processing subsystem. The processing subsystem is configured to execute on a network to control bidirectional communications among a plurality of modules. The processing subsystem includes an ultra-sonic sensor. The ultra-sonic sensor is adapted to detect a home position of the refractory checker. The processing subsystem includes a servo motor operatively coupled to the ultra-sonic sensor. The servo motor is adapted to rotate the rotating base plate at a pre-defined speed and at a pre-defined angle in conjunction with rotating the refractory checker. The processing subsystem includes a laser sensor mounted on a measuring pole and operatively coupled to the ultra-sonic sensor. The laser sensor is adapted to capture a measurable distance and a fixed height distance. The measurable distance is the distance between the measuring pole and surface of the refractory checker of a plurality of predefined points. The fixed height distance is the distance from the rotating base plate for each predefined point. The data from the laser sensor is captured through a universal serial bus device. The processing subsystem includes an analyzing module operatively coupled to the laser sensor. The analyzing module is adapted to calculate the height of the refractory checker by analyzing the measurable distance and the fixed height distance for the plurality of predefined points. The processing subsystem includes a display module operatively coupled to the analyzing module. The display module is adapted to render a plurality of results. The plurality of results includes a color corresponding to the height range of the refractory checker. The color represents an acceptable range of height. The processing subsystem includes an alert module operatively coupled to the display module. The alert module is adapted to alert the user if the measured height exceeds a predefined threshold thereby indicating the need for rework by grinding the refractory checker to meet a required height. The processing subsystem includes a feedback module operatively coupled to the alert module. The feedback module is adapted to provide feedback to the user by classifying the refractory checker as accepted, rejected, or marked for rework based on the measured heights relative to the predefined threshold value.
[0011] In accordance with another embodiment of the present disclosure, a method to operate a system for contactless height measurement of a refractory checker is provided. The method includes allowing by a control panel equipped with a power switch, a user to activate the system. The method includes holding, by a rotating base plate, the refractory checker for height measurement. The method includes detecting by an ultra-sonic sensor, a home position of the refractory checker. The method includes rotating, by a servo motor, the rotating base plate at a pre-defined speed and at a pre-defined angle in conjunction with rotating the refractory checker. The method includes capturing, by a laser sensor mounted on a measuring pole, a measurable distance and a fixed height distance. The measurable distance is distance between the measuring pole and surface of the refractory checker of a plurality of predefined points. The fixed height distance is the distance from the rotating base plate for each predefined points wherein data from the laser sensor is captured through a universal serial bus device. The method includes calculating, by an analyzing module, the height of the refractory checker by analyzing the measurable distance and the fixed height distance for the plurality of predefined points. The method includes rendering by a display module, a plurality of results. The plurality of results includes a color corresponding to the height range of the refractory checker. The color represents an acceptable range of height. The method includes alerting, by an alert module, the user if the measured height exceeds a predefined threshold thereby indicating the need for rework by grinding the refractory checker to meet a required height. The method includes providing, by a feedback module, feedback to the user by classifying the refractory checker as accepted, rejected, or marked for rework based on the measured heights relative to the predefined threshold value.
[0012] To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:
[0014] FIG. 1 is a schematic representation of a system for contactless height measurement of a refractory checker in accordance with an embodiment of the present disclosure;
[0015] FIG. 2 is a schematic representation of placement of a refractory checker of FIG. 1 in accordance with an embodiment of the present disclosure;
[0016] FIG. 3 is a block diagram of a computer or a server in accordance with an embodiment of the present disclosure;
[0017] FIG. 4(a) illustrates a flow chart representing the steps involved in a method to operate a system for contactless height measurement of a refractory checker in accordance with an embodiment of the present disclosure; and
[0018] FIG. 4(b) illustrates continued steps of the method of FIG. 4 (a) in accordance with an embodiment of the present disclosure.
[0019] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION
[0020] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.
[0021] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or subsystems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
[0023] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
[0024] Embodiments of the present disclosure relates to a system for contactless height measurement of a refractory checker. The system includes a control panel equipped with a power switch. The power switch is adapted to allow a user to activate the system. The system includes a rotating base plate operatively coupled to the control panel. The rotating base plate is adapted to hold the refractory checker for height measurement. The system includes a processing subsystem. The processing subsystem is configured to execute on a network to control bidirectional communications among a plurality of modules. The processing subsystem includes an ultra-sonic sensor. The ultra-sonic sensor is adapted to detect a home position of the refractory checker. The processing subsystem includes a servo motor operatively coupled to the ultra-sonic sensor. The servo motor is adapted to rotate the rotating base plate at a pre-defined speed and at a pre-defined angle in conjunction with rotating the refractory checker. The processing subsystem includes a laser sensor mounted on a measuring pole and operatively coupled to the ultra-sonic sensor. The laser sensor is adapted to capture a measurable distance and a fixed height distance. The measurable distance is the distance between the measuring pole and surface of the refractory checker of a plurality of predefined points. The fixed height distance is the distance from the rotating base plate for each predefined point. The data from the laser sensor is captured through a universal serial bus device. The processing subsystem includes an analyzing module operatively coupled to the laser sensor. The analyzing module is adapted to calculate the height of the refractory checker by analyzing the measurable distance and the fixed height distance for the plurality of predefined points. The processing subsystem includes a display module operatively coupled to the analyzing module. The display module is adapted to render a plurality of results. The plurality of results includes a color corresponding to the height range of the refractory checker. The color represents an acceptable range of height. The processing subsystem includes an alert module operatively coupled to the display module. The alert module is adapted to alert the user if the measured height exceeds a predefined threshold thereby indicating the need for rework by grinding the refractory checker to meet a required height. The processing subsystem includes a feedback module operatively coupled to the alert module. The feedback module is adapted to provide feedback to the user by classifying the refractory checker as accepted, rejected, or marked for rework based on the measured heights relative to the predefined threshold value.
[0025] FIG. 1 is a block diagram of a system (100) for contactless height measurement of a refractory checker (120) in accordance with an embodiment of the present disclosure. The refractory checkers are used for stove, furnace, heat exchangers and the like. The system (100) includes a control panel (125) equipped with a power switch (130). The power switch (130) is adapted to allow a user to activate the system (100). The power switch (130) is positioned in a readily accessible location on the control panel (125). The power switch (130) includes one of a toggle, push-button, rocker switch and the like, depending on the design requirements of the system (100).
[0026] In one embodiment, the power switch (130) is integrated with status indicators, such as light emitting diode (LED) lights, to visually communicate whether the system (100) is active.
[0027] The system (100) includes a rotating base plate (135) operatively coupled to the control panel (125). The rotating base plate (135) is adapted to hold the refractory checker (120) for height measurement. The rotation of the rotating base plate (135) begins and ends at a home position (180), ensuring a single rotation cycle in the height measurement process.
[0028] The system (100) includes a processing subsystem (105) hosted on a server (108). In one embodiment, the server (108) may include a cloud-based server. In another embodiment, parts of the server (108) may be a local server coupled to a user device (not shown in FIG.1). The processing subsystem (105) is configured to execute on a network (115) to control bidirectional communications among a plurality of modules. In one example, the network (115) may be a private or public local area network (LAN) or Wide Area Network (WAN), such as the Internet. In another embodiment, the network (115) may include both wired and wireless communications according to one or more standards and/or via one or more transport mediums. In one example, the network (115) may include wireless communications according to one of the 802.11 or Bluetooth specification sets, or another standard or proprietary wireless communication protocol. In yet another embodiment, the network (115) may also include communications over a terrestrial cellular network, including, a global system for mobile communications (GSM), code division multiple access (CDMA), and/or enhanced data for global evolution (EDGE) network.
[0029] The processing subsystem (105) includes an ultra-sonic sensor (140). The ultra-sonic sensor (140) is adapted to detect the home position (180) of the refractory checker (120). The ultra-sonic sensor (140) operates using ultrasonic waves to measure distances and identify specific positions. The ultrasonic sensor (140) uses a transducer to send and receive ultrasonic pulses that relay back information about the refractory checker’s proximity.
[0030] The processing subsystem (105) includes a servo motor (145) operatively coupled to the ultra-sonic sensor (140). The servo motor (145) is adapted to rotate the rotating base plate (135) at a pre-defined speed and at a pre-defined angle in conjunction with rotating the refractory checker (120). The servo motor (145) is a rotary actuator that allows for precise control of angular position. The servo motor (145) consists of a motor coupled to the ultra-sonic sensor (140) for position feedback.
[0031] In an embodiment, a proximity sensor is operatively coupled to the servo motor (145). The proximity sensor is adapted to trigger a height measurement process upon detecting the refractory checker (120) is positioned at the home position (180).
[0032] The processing subsystem (105) includes a laser sensor (150) mounted on a measuring pole and operatively coupled to the ultra-sonic sensor (140). The laser sensor (150) is adapted to capture a measurable distance and a fixed height distance. The measurable distance is the distance between the measuring pole and surface of the refractory checker (120) of a plurality of predefined points. The fixed height distance is the distance from the rotating base plate (135) for each predefined point. The data from the laser sensor (150) is captured through a universal serial bus device. The plurality of predefined points is located on a straight surface of the refractory checker (120). The number of the plurality of predefined points is based on the design of the refractory checker (120).
[0033] In an embodiment, the predefined points consist of 12 points, corresponding to the straight sides of the refractory checker (120), which are referred to as ribs. The refractory checker (120) features 12 such ribs. Specifically, the refractory checker (120) has 12 curved sides and 12 straight sides (ribs).
[0034] The processing subsystem (105) includes an analyzing module (155) operatively coupled to the laser sensor (150). The analyzing module (155) is adapted to calculate the height of the refractory checker (120) by analyzing the measurable distance and the fixed height distance for the plurality of predefined points.
[0035] The processing subsystem (105) includes a display module (160) operatively coupled to the analyzing module (155). The display module (160) is adapted to render a plurality of results. The plurality of results includes a color corresponding to the height range of the refractory checker (120). The color represents an acceptable range of height. Color coding is used for identifying and categorizing the ribs based on preset height standards. The system (100) is designed to accommodate industrial requirements by allowing the user to a predefined threshold that defines what is considered acceptable, what requires rework, and what should be rejected. For example, if the height of all the 12 ribs falls within a particular color range, the checker is deemed acceptable. Ribs that do not meet these criteria are categorized either for rework or rejection based on the predefined threshold. The display module (160) includes a Human-machine interface (HMI) (175). HMI (175) is a user interface or dashboard that connects a person to a machine, system, or device. While the term can technically be applied to any screen that allows a user to interact with a device, HMI (175) is most used in the context of an industrial process. Basic HMI (175) examples include built-in screens on machines, computer monitors, and tablets, but regardless of their format or which term you use to refer to them, their purpose is to provide insight into mechanical performance and progress. HMI (175) visualizes data such as measurements, operational statuses, and system alerts. The HMI (175) provides immediate real-time feedback based on user input and system outputs.
[0036] The processing subsystem (105) includes an alert module (165) operatively coupled to the display module (160). The alert module (165) is adapted to alert the user if the measured height exceeds the predefined threshold thereby indicating the need for rework by grinding the refractory checker (120) to meet a required height.
[0037] The processing subsystem (105) includes a feedback module (170) operatively coupled to the alert module (165). The feedback module (170) is adapted to provide feedback to the user by classifying the refractory checker (120) as accepted, rejected, or marked for rework based on the measured heights relative to the predefined threshold value. The feedback module (170) includes at least one of light emitting diode and a buzzer. LEDs may be used to represent different statuses through various colors.
[0038] In one embodiment, a green LED might indicate that the refractory checker (120) has been accepted, indicating that the measured height is within the acceptable range. A buzzer sound indicates that the refractory checker (120) has been rejected due to the height falling outside the acceptable range. A separate Green LED will blink along with Black, White, Green, Blue yellow and Red LED indicates that the refractory checker (120) requires rework. Perhaps the height is close to the predefined threshold but not within the desired specifications.
[0039] Further, the system (100) comprises a calibration mark affixed to the rotating base plate (135). The calibration mark is adapted to mark the home position (180) for ensuring the rotation of the rotating base plate (135) is correctly aligned with the home position (180).
[0040] Let’s consider an example, wherein a user “X” wants to measure the height of a refractory checker before being used in a regenerative or recuperative furnace. Initially, user “X” switches on the system by activating the power switch located on the control panel. Upon doing so, the Human-Machine Interface (HMI) displays a welcome screen. Further, user X places the refractory checker on top of the rotating base plate, which cautioned against pressing the home switch without the refractory checker properly in place at the home position. Once the refractory checker is positioned correctly, User X presses the "HOME" switch. This leads to the rotation of the rotating base plate. As it turned, the proximity sensor or ultra-sensor detected the presence of the refractory checker. The system proceeded to check 12 distinct points called ribs on the refractory checker to evaluate its dimensions using a laser sensor positioned on the measuring pole. As and when a single measurement cycle concluded, the results were displayed on the HMI and the control panel. The display indicated the color corresponding to the height range of the refractory checker. In scenarios where the refractory checker measurements fell within a rework tolerance band, the relevant color on the HMI and a rework LED started blinking to alert User X of the need for adjustments. Conversely, if the refractory checker was found to be unacceptable, a rejection LED lit up accompanied by an audible buzzer, signaling that the refractory checker failed to meet the required specifications and could not be used in the furnace.
[0041] It is to be noted that the system may comprise, but is not limited to, a mobile phone, desktop computer, portable digital assistant (PDA), smart phone, tablet, ultra-book, netbook, laptop, multi-processor system, microprocessor-based or programmable consumer electronic system, or any other communication device that a user may use. In some embodiments, the system may comprise a display module (160) display information (for example, in the form of user interfaces). In further embodiments, the system may comprise one or more of touch screens, accelerometers, gyroscopes, cameras, microphones, global positioning system (GPS) devices, and so forth.
[0042] In one embodiment, the various functional components of the system may reside on a single computer, or they may be distributed across several computers in various arrangements. The various components of the system may, furthermore, access one or more databases, and each of the various components of the system may be in communication with one another. Further, while the components of FIG. 1 are discussed in the singular sense, it will be appreciated that in other embodiments multiple instances of the components may be employed.
[0043] FIG. 2 is a schematic representation of placement of a refractory checker (120) of FIG. 1 in accordance with an embodiment of the present disclosure. The schematic representation showcases the refractory checker (120) positioned above the rotating base plate (135) within the system (100), highlighting its alignment and interaction with system (100) components such as sensors and the control panel (125). The calibration mark, which is essential for ensuring correct alignment, is strategically placed just above the home position (180) on the rotating base plate (135). As the rotating base plate (135) returns to this home position (180), the ultra-sonic sensor (140) verifies its alignment while the laser sensor (150) measures distances from various points on the refractory checker (120). The data collected from both sensors are captured, analyzed, and displayed on the display module (160) via a Human-Machine Interface (HMI), ensuring accurate and reliable height measurements.
[0044] FIG. 3 is a block diagram of a computer or a server in accordance with an embodiment of the present disclosure. The server (200) includes processor(s) (230), and memory (210) operatively coupled to the bus (220). The processor(s) (230), as used herein, means any type of computational circuit, such as, but not limited to, a microprocessor, a microcontroller, a complex instruction set computing microprocessor, a reduced instruction set computing microprocessor, a very long instruction word microprocessor, an explicitly parallel instruction computing microprocessor, a digital signal processor, or any other type of processing circuit, or a combination thereof.
[0045] The memory (210) includes several subsystems stored in the form of executable program which instructs the processor (230) to perform the method steps illustrated in FIG. 1. The memory (210) includes a processing subsystem (105) of FIG.1. The processing subsystem (105) further has following modules: an ultra-sonic sensor (140), a servo motor (145), a laser sensor (150), an analyzing module (155), a display module (160), an alert module (165) and a feedback module (170).
[0046] In accordance with an embodiment of the present disclosure, a system (100) for contactless height measurement of a refractory checker (120) is provided. The system (100) includes a control panel (125) equipped with a power switch (130). The power switch (130) is adapted to allow a user to activate the system (100). The system (100) includes a rotating base plate (135) operatively coupled to the control panel (125). The rotating base plate (135) is adapted to hold the refractory checker (120) for height measurement. The system (100) includes a processing subsystem (105). The processing subsystem (105) is configured to execute on a network (115) to control bidirectional communications among a plurality of modules. The processing subsystem (105) includes an ultra-sonic sensor (140). The ultra-sonic sensor (140) is adapted to detect a home position (180) of the refractory checker (120). The processing subsystem (105) includes a servo motor (145) operatively coupled to the ultra-sonic sensor (140). The servo motor (145) is adapted to rotate the rotating base plate (135) at a pre-defined speed and at a pre-defined angle in conjunction with rotating the refractory checker (120). The processing subsystem (105) includes a laser sensor (150) mounted on a measuring pole and operatively coupled to the ultra-sonic sensor (140). The laser sensor (150) is adapted to capture a measurable distance and a fixed height distance. The measurable distance is the distance between the measuring pole and surface of the refractory checker (120) of a plurality of predefined points. The fixed height distance is the distance from the rotating base plate (135) for each predefined point. The data from the laser sensor (150) is captured through a universal serial bus device. The processing subsystem (105) includes an analyzing module (155) operatively coupled to the laser sensor (150). The analyzing module (155) is adapted to calculate the height of the refractory checker (120) by analyzing the measurable distance and the fixed height distance for the plurality of predefined points. The processing subsystem (105) includes a display module (160) operatively coupled to the analyzing module (155). The display module (160) is adapted to render a plurality of results. The plurality of results includes a color corresponding to the height range of the refractory checker (120). The color represents an acceptable range of height. The processing subsystem (105) includes an alert module (165) operatively coupled to the display module (160). The alert module (165) is adapted to alert the user if the measured height exceeds a predefined threshold thereby indicating the need for rework by grinding the refractory checker (120) to meet a required height. The processing subsystem (105) includes a feedback module (170) operatively coupled to the alert module (165). The feedback module (170) is adapted to provide feedback to the user by classifying the refractory checker (120) as accepted, rejected, or marked for rework based on the measured heights relative to the predefined threshold value.
[0047] The bus (220) as used herein refers to internal memory channels or computer network that is used to connect computer components and transfer data between them. The bus (220) includes a serial bus or a parallel bus, wherein the serial bus transmits data in bit-serial format and the parallel bus transmits data across multiple wires. The bus (220), as used herein, may include but not limited to, a system bus, an internal bus, an external bus, an expansion bus, a frontside bus, a backside bus and the like.
[0048] FIG. 4(a) illustrates a flow chart representing the steps involved in a method (300) to operate a system for contactless height measurement of a refractory checker in accordance with an embodiment of the present disclosure. FIG. 4(b) illustrates continued steps of the method (300) of FIG. 4 (a) in accordance with an embodiment of the present disclosure. The method (300) includes allowing by a control panel equipped with a power switch, a user to activate the system in step 305. The power switch is positioned in a readily accessible location on the control panel. The power switch includes one of a toggle, push-button, rocker switch and the like, depending on the design requirements of the system.
[0049] In one embodiment, the power switch is integrated with status indicators, such as light emitting diode (LED) lights, to visually communicate whether the system is active.
[0050] The method (300) includes holding, by a rotating base plate, the refractory checker for height measurement in step 310. The rotation of the rotating base plate begins and ends at a home position, ensuring a single rotation cycle in the height measurement process.
[0051] The method (300) includes detecting by an ultra-sonic sensor, a home position of the refractory checker in step 315. The ultra-sonic sensor operates using ultrasonic waves to measure distances and identify specific positions. The ultrasonic sensor uses a transducer to send and receive ultrasonic pulses that relay back information about the refractory checker’s proximity.
[0052] The method (300) includes rotating, by a servo motor, the rotating base plate at a pre-defined speed and at a pre-defined angle in conjunction with rotating the refractory checker in step 320. The servo motor is a rotary actuator that allows for precise control of angular position. The servo motor consists of a motor coupled to the ultra-sonic sensor for position feedback.
[0053] The method (300) includes capturing, by a laser sensor mounted on a measuring pole, a measurable distance and a fixed height distance. The measurable distance is distance between the measuring pole and surface of the refractory checker of a plurality of predefined points. The fixed height distance is the distance from the rotating base plate for each predefined points wherein data from the laser sensor is captured through a universal serial bus device in step 325. The plurality of predefined points is located on a straight surface of the refractory checker. The number of the plurality of predefined points is based on the design of the refractory checker.
[0054] In an embodiment, the predefined points consist of 12 points, corresponding to the straight sides of the refractory checker, which are referred to as ribs. The refractory checker features 12 such ribs. Specifically, the refractory checker has 12 curved sides and 12 straight sides (ribs). For other design checkers the number of ribs vary from 6 to 12 to 19 to 26 and more.
[0055] The method (300) includes calculating, by an analyzing module, the height of the refractory checker by analyzing the measurable distance and the fixed height distance for the plurality of predefined points in step 330.
[0056] The method (300) includes rendering by a display module, a plurality of results. The plurality of results includes a color corresponding to the height range of the refractory checker. The color represents an acceptable range of height in step 335. The system is designed to accommodate industrial requirements by allowing the user to a predefined threshold that defines what is considered acceptable, what requires rework, and what should be rejected. For example, if the height of all 12 ribs falls within a particular color range, the checker is deemed acceptable. Ribs that do not meet these criteria are categorized either for rework or rejection based on the predefined threshold. The display module includes a Human-machine interface (HMI). HMI is a user interface or dashboard that connects a person to a machine, system, or device. While the term can technically be applied to any screen that allows a user to interact with a device, HMI is most used in the context of an industrial process. Basic HMI examples include built-in screens on machines, computer monitors, and tablets, but regardless of their format or which term you use to refer to them, their purpose is to provide insight into mechanical performance and progress. HMI visualizes data such as measurements, operational statuses, and system alerts. The HMI provides immediate real-time feedback based on user input and system outputs.
[0057] The method (300) includes alerting, by an alert module, the user if the measured height exceeds a predefined threshold thereby indicating the need for rework by grinding the refractory checker to meet a required height in step 340.
[0058] The method (300) includes providing, by a feedback module, feedback to the user by classifying the refractory checker as accepted, rejected, or marked for rework based on the measured heights relative to the predefined threshold value in step 345. The feedback module includes at least one of light emitting diode and a buzzer.
[0059] Various embodiments of the system and a method for contactless height measurement of a refractory checker as described above simplifying the process of height measurement of a refractory checker with the integration of color-coded results for height ranges displayed on the HMI. The system categorizes each refractory checker based on predefined height standards. Should the refractory checker fail to meet the necessary specifications, the system promptly alerts the operator with visual (LED indicators) and auditory (buzzer) signals for necessary rework or rejection. The data capture of each measurement enhances data analysis, leading to increased yield, reduced worker fatigue, and improved working ergonomics. Moreover, this system minimizes eye strain, increases accuracy, lowers maintenance costs, decreases dependency on manual labor, and eliminates the need for specialized skills in operation.
[0060] The techniques described in this disclosure may be implemented, at least in part, in hardware, software, firmware, or any combination thereof. For example, various aspects of the described techniques may be implemented within one or more processors, including one or more microprocessors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or any other equivalent integrated or discrete logic circuitry, as well as any combinations of such components. The term “processor” or “processing subsystem” may generally refer to any of the foregoing logic circuitry, alone or in combination with other logic circuitry, or any other equivalent circuitry. A control unit including hardware may also perform one or more of the techniques of this disclosure.
[0061] Such hardware, software, and firmware may be implemented within the same device or within separate devices to support the various techniques described in this disclosure. In addition, any of the described units, modules, or components may be implemented together or separately as discrete but interoperable logic devices. Depiction of different features as modules or units is intended to highlight different functional aspects and does not necessarily imply that such modules or units must be realized by separate hardware, firmware, or software components. Rather, functionality associated with one or more modules or units may be performed by separate hardware, firmware, or software components, or integrated within common or separate hardware, firmware, or software components.
[0062] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.
[0063] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
[0064] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.
, Claims:1. A system (100) for contactless height measurement of a refractory checker (120) comprising:
a control panel (125) equipped with a power switch (130), wherein the power switch (130) is adapted to allow a user to activate the system (100);
characterized in that,
a rotating base plate (135) operatively coupled to the control panel (125), wherein the rotating base plate (135) is adapted to hold the refractory checker (120) for height measurement; and
a processing subsystem (105) hosted on a server (108) and configured to execute on a network (115) to control bidirectional communications among a plurality of modules, wherein the plurality of modules comprising:
an ultra-sonic sensor (140), wherein the ultra-sonic sensor (140) is adapted to detect a home position (180) of the refractory checker (120);
a servo motor (145) operatively coupled to the ultra-sonic sensor (140), wherein the servo motor (145) is adapted to rotate the rotating base plate (135) at a pre-defined speed and at a pre-defined angle in conjunction with rotating the refractory checker (120);
a laser sensor (150) mounted on a measuring pole and operatively coupled to the ultra-sonic sensor (140), wherein the laser sensor (150) is adapted to capture a measurable distance and a fixed height distance, wherein the measurable distance is distance between the measuring pole and surface of the refractory checker (120) of a plurality of predefined points, wherein the fixed height distance is the distance from the rotating base plate (135) for each predefined points wherein data from the laser sensor (150) is captured through an universal serial bus device;
an analyzing module (155) operatively coupled to the laser sensor (150), wherein the analyzing module (155) is adapted to calculate the height of the refractory checker (120) by analyzing the measurable distance and the fixed height distance for the plurality of predefined points;
a display module (160) operatively coupled to the analyzing module (155), wherein the display module (160) is adapted to render a plurality of results, wherein the plurality of results comprises a color corresponding to the height range of the refractory checker (120), wherein the color represents an acceptable range of height;
an alert module (165) operatively coupled to the display module (160), wherein the alert module (165) is adapted to alert the user if the measured height exceeds a predefined threshold thereby indicating the need for rework by grinding the refractory checker (120) to meet a required height; and
a feedback module (170) operatively coupled to the alert module (165), wherein the feedback module (170) is adapted to provide feedback to the user by classifying the refractory checker (120) as accepted, rejected, or marked for rework based on the measured heights relative to the predefined threshold value.
2. The system (100) as claimed in claim 1, wherein the display module (160) comprises a Human-machine interface (175).

3. The system (100) as claimed in claim 1, wherein the plurality of predefined points is located on a straight surface of the refractory checker (120), wherein the number of the plurality of predefined points is based on the design of the refractory checker (120).

4. The system (100) as claimed in claim 1, wherein the rotation of the rotating base plate (135) begins and ends at the home position (180), ensuring a single rotation cycle in the height measurement process.

5. The system (100) as claimed in claim 1, wherein the feedback module (170) comprises at least one of light emitting diode and a buzzer.

6. The system (100) as claimed in claim 1, comprising a calibration mark affixed to the rotating base plate (135), wherein the calibration mark is adapted to mark the home position (180) for ensuring the rotation of the rotating base plate (135) is correctly aligned with the home position (180).

7. The system (100) as claimed in claim 1, comprising a proximity sensor operatively coupled to the servo motor (145), wherein the proximity sensor is adapted to trigger a height measurement process upon detecting the refractory checker (120) is positioned at the home position (180).

8. A method (300) to operate a system for contactless height measurement of a refractory checker comprising:

allowing by a control panel equipped with a power switch, a user to activate the system; (305)
characterized in that,
holding, by a rotating base plate, the refractory checker for height measurement; (310)
detecting by an ultra-sonic sensor, a home position of the refractory checker; (315)
rotating, by a servo motor, the rotating base plate at a pre-defined speed and at a pre-defined angle in conjunction with rotating the refractory checker; (320)
capturing, by a laser sensor mounted on a measuring pole, a measurable distance and a fixed height distance, wherein the measurable distance is distance between the measuring pole and surface of the refractory checker of a plurality of predefined points, wherein the fixed height distance is the distance from the rotating base plate for each predefined points wherein data from the laser sensor is captured through a universal serial bus device; (325)
calculating, by an analyzing module, the height of the refractory checker by analyzing the measurable distance and the fixed height distance for the plurality of predefined points; (330)
rendering by a display module, a plurality of results, wherein the plurality of results comprises a color corresponding to the height range of the refractory checker, wherein the color represents an acceptable range of height; (335)
alerting, by an alert module, the user if the measured height exceeds a predefined threshold thereby indicating the need for rework by grinding the refractory checker to meet a required height; and (340)
providing, by a feedback module, feedback to the user by classifying the refractory checker as accepted, rejected, or marked for rework based on the measured heights relative to the predefined threshold value. (345)

Dated this 19th day of June 2024
Signature

Jinsu Abraham
Patent Agent (IN/PA-3267)
Agent for the Applicant