Method and apparatus to monitor/detect nodularization in ductile iron
View Patent ↗The present invention is direct to a method/apparatus for verifying a nodularization process in a molten iron disposed within a ladle. The method includes the steps of: transferring the ladle with the molten iron to a nodularization area; adding an amount of magnesium to the molten iron in the ladle for producing the nodularization process in the molten iron; measuring vibration of the ladle containing the molten iron caused by the nodularization process in the molten iron; comparing the measured vibration with a predetermined level of vibration; and determining that the nodularization process occurs if the measured vibration is higher than the predetermined level of vibration.
1. A method for verifying a nodularization process in a molten iron disposed within a ladle, said method comprising the steps of:
transferring said ladle with said molten iron to a nodularization area;
adding an amount of magnesium to said molten iron in said ladle for producing said nodularization process in said molten iron;
measuring vibration of said ladle containing said molten iron caused by said nodularization process in said molten iron;
comparing said measured vibration with a predetermined level of vibration; and
determining that said nodularization process occurs if said measured vibration is higher than said predetermined level of vibration.
2. The method according to claim 1 , further comprising the step of:
locking said ladle to prevent transfer of said ladle during said nodularization process.
3. The method according to claim 2 , wherein said step of locking said ladle responds to a signal generated during said step of determining that said nodularization process occurs.
4. The method according to claim 1 , wherein said step of measuring vibration of said ladle includes measuring displacement of said ladle from a rest position.
5. The method according to claim 4 , wherein said displacement is within about plus or minus seven tenths of an inch from said rest position.
6. The method of claim 4 , wherein said step of measuring displacement of said ladle employs a laser sensing unit to measure said displacement of said ladle.
7. The method of claim 6 , further comprising the step of calibrating said laser sensing unit prior to said step of adding said magnesium.
8. The method according to claim 7 , wherein prior to adding said amount of magnesium, said step of calibrating said laser sensing unit includes pulsing said laser sensing unit and creating a mapping signature of said ladle.
9. The method according to claim 8 , wherein said nodularization process is determined when a displacement of said vibration of said ladle exceeds a predetermined distance after said amount of magnesium is added.
10. The method according to claim 9 , wherein said displacement of said ladle exceeds said predetermined distance when said displacement of said ladle deviates seven tenths of one inch from said mapping signature.
11. The method according to claim 1 , further comprising the step of starting a timer when said nodularization process is determined.
12. The method according to claim 11 , further comprising the step of pouring said molten iron after a predetermined amount of time.
13. The method according to claim 12 , further comprising the step of calculating said predetermined amount of time.
14. The method according to claim 11 , further comprising, the step of implementing a warning system to ensure that the ladle is poured within a specified time frame after said nodularization process has occurred.
15. The method according to claim 1 , further comprising the step of utilizing a computer system to automate control of each of said steps of: transferring said ladle; adding an amount of magnesium to said molten iron; measuring vibration of said ladle; comparing said measured vibration; and determining that said nodularization process occurs.
16. The method according to claim 1 , further comprising the steps of:
locking said ladle to prevent transfer of said ladle during said nodularization process in response to a signal generated during said step of determining that said nodularization process occurs;
pouring said molten iron after a predetermined amount of time after determining that said nodularization process occurs;
wherein said step of measuring vibration of said ladle includes measuring displacement of said ladle from a rest position
said step of measuring vibration of said ladle includes measuring displacement of said ladle from a rest position utilizing a laser sensing unit; and
implementing a warning system to ensure that the ladle is poured within a specified time frame after said nodularization process has occurred.
17. The method according to claim 16 ; further comprising the step of utilizing a computer system to automate control of each of said steps of: transferring said ladle; adding said amount of magnesium to said molten iron; measuring vibration of said ladle; comparing said measured vibration; determining that said nodularization process occurs, locking said ladle, pouring said molten iron, and implementing said warning system.