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Anonymous Poster #1

Question on available sensor... "metal on metal"

02/11/2016 12:19 PM

Hello,

What I want to know: is there a tech out there that can sense when a latch/hook is in place?

Imagine a cauldron getting picked up and moved around, is there a way I know for sure that the hook is actually attacked?

Basically I'm trying to find out if a latch is attached/or in an extremely high temp (~1800+F) environment. I would like a fail safe system built into my design so that even if the operator falls asleep, he/she won't be able to press the "go" button.

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#1

Re: Question on available sensor... "metal on metal"

02/11/2016 12:56 PM

I wish I could say there was a relay with a connected machine vision module and a button to save the image associated with opening and closing the relay contacts, but there's not.

I've used a lot of magnetic switches can be modified to do just about anything, but in your environment you would need them to be as far away from the 1800 fits as possible.

Pictures would be helpful

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#2

Re: Question on available sensor... "metal on metal"

02/11/2016 1:38 PM

Are you trying to determine if the cauldron is attached or that it is safely attached & won't fall off? If you just want to know that the cauldron is there, a load cell in the crane (away from the heat) would do.

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Anonymous Poster #1
#3
In reply to #2

Re: Question on available sensor... "metal on metal"

02/11/2016 2:41 PM

Oh man, I should've mention this... but not only will it be INSIDE with the heat, it'll be submerge in water at the same time.

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#7
In reply to #3

Re: Question on available sensor... "metal on metal"

02/11/2016 3:24 PM

1800º water! ?!

a series of rod and cable connected to a switch.

a little custom fabrication.

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#8
In reply to #3

Re: Question on available sensor... "metal on metal"

02/11/2016 3:24 PM

Water at 1800degF is fearsome stuff, because of the pressure needed to keep it liquid at that temperature, <...man...>!

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#4

Re: Question on available sensor... "metal on metal"

02/11/2016 3:08 PM

Chain or wire line load cell. Using the difference in load being sensed as a safety factor.

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#5

Re: Question on available sensor... "metal on metal"

02/11/2016 3:08 PM

What type of hook assembly are we talking about...?

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Anonymous Poster #1
#11
In reply to #5

Re: Question on available sensor... "metal on metal"

02/11/2016 4:06 PM

This is what I'm talking about, but it might be smaller.

""

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#12
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Re: Question on available sensor... "metal on metal"

02/11/2016 4:26 PM

so where's the latch? Seems outrageous to be quite honest

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#19
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Re: Question on available sensor... "metal on metal"

02/12/2016 9:13 AM

Ok, so where's the water, Mildred?

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#6

Re: Question on available sensor... "metal on metal"

02/11/2016 3:22 PM

There is a contradiction 1800°F and Water. Could you clear it ?

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#22
In reply to #6

Re: Question on available sensor... "metal on metal"

02/12/2016 10:38 AM

If the water's at 1,800ºF and a pressure seal fails, it'll 'clear' pretty quick.

It'll clear the whole BUILDING into a smoking crater.

That might be entertaining to watch, from a safe distance. do you think the 'hyper-steam(1)' would form a mushroom cloud as it rises?

Notes:

  1. I picked up the term from an old British 'Crack-pot inventor and various children go off on an adventure in one of his inventions' movie. I forget the name of the movie, but the term stuck, I use it for referring to 'superheated/high-pressure steam,' anything above 212ºF and/or 1 atmosphere of pressure(2).
  2. Fun fact, kids, you can make hypersteam at home(3)! just fill a heat-resistant glass container with water, put it in the microwave, and 'nuke' until all the water boils away. The steam inside the microwave is hotter than normal steam, since it could not get out and get away from the microwave radiation, so after the water boiled it just kept getting hotter, and hotter, and hotter...
  3. Please note: you should NOT try this at home! No! Not under any circumstances, there is an extremely high risk of severe burns. Just because something CAN be done does not mean it SHOULD be done. It's like mixing ammonia and bleach; yes it is POSSIBLE to bring these two household chemicals together, but it should NEVER be done, it can KILL people.
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#24
In reply to #22

Re: Question on available sensor... "metal on metal"

02/12/2016 1:30 PM

I love this.

Why do we all feel compelled to tell how to do something very dangerous, and immediately say "NEVER do this"? That is definitely a common human trait. There must be a psychoanalysis term for this.

I mean, you KNOW someone is definitely going to try that, don't you?

Don't feel bad - I do the same thing.

Yes, I believe a mushroom cloud would form. That is not unique to A bombs. Many explosions create one, just not as long lasting or impressive as an A bomb.

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#25
In reply to #24

Re: Question on available sensor... "metal on metal"

02/12/2016 2:31 PM

As to the 'why I said that,' it was A) a case of my Mad Scientist side peaking out to sow chaos (ineffectively, I might add, this is not a site where I would EXPECT impressionable young kids to visit), and B) I've made microwaved hypersteam by accident several times, and in fact, it's likely that there are 'tv dinners' that end up producing 250-300ºF hypersteam by following the directions on the package, typically the ones that have PRODUCT WILL BE HOT as part of the cooking instructions.

As to the mushroom cloud comment, I'm well aware that any explosion with enough energy to create a thermal updraft will form the mushroom cloud shape. I was bringing that up just to lighten the mood. I've seen the Mythbusters episode on exploding water heaters(1), and when they had their thermocouple failure and had to abort the first test, with the water at a 'mere, 250-300 degrees, their exhaust pipe nearly rips off the rig from the force of the flash steam. Knowing that, and trying to visualize how much energy would be contained in water at 1,500 degrees and under such pressure that it's still liquid, and what would happen if there were a leak that allowed it to flash into steam, that was simply horrible to imagine, so I had to step back and make a snarky joke out of it, to protect what I jokingly call my sanity.

Notes:

  1. A topic I took as common knowledge, before the invention of the T&P valve, defective water heaters in Chicago would rocket through a 2 story Brownstone(2) and land several blocks away.
  2. Built to Chicago Building Code, unlike the 'rickety shacks' the Mythbusters built according to CA codes for their show.
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#27
In reply to #25

Re: Question on available sensor... "metal on metal"

02/12/2016 3:23 PM

Yes, but I still wonder what that "Mad Scientist" tendency is called? I'm sure, since so many of us have that side to us, the shrinks have a term for it. I found a term for the questionable tendencies so many seem to have to build or stay in obvious disaster prone areas that came about from a post by Fredski showing houses on the edge of a cliff about to nose dive into the water. If that has a name, so does the mad scientist thing. Google hasn't found it for me yet.

I'm into these strange mental quirks, as I have a number of them and have found named diseases to describe all of them. My worst is misophonia. Check it out. And everyone thought I was just nuts when I told them to be quiet.

You need to figure how many cubic feet a known quantity of water will expand to when it becomes steam to get a grasp on the damage to be done if 1500 degree water lost containment. High pressure liquid doesn't scare me - high pressure gas does.

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#29
In reply to #27

Re: Question on available sensor... "metal on metal"

02/12/2016 3:56 PM

"Yes, but I still wonder what that "Mad Scientist" tendency is called?"

One description I've heard is SRMD: Science-Related Memetic Disorder. Symptoms can include:

  • Maniacal laughter
  • Excessive hand wringing
  • Stylized and dramatic poses
  • Poor volume control when excited
  • Excessive use of bad puns and dark humor
  • Altered mental states:
    • Delusions of Grandeur
    • Delusions of Competence
    • Delusions of Schizophrenia When you think you're crazier than you really are.)
    • Delusions of Sanity (When you THINK you're not crazy, but you really are.)

Of course, all this may be due to 'pop cultural osmosis.' After all, who in this country HASN'T seen at least one of the laughably bad B-list horror movies of the 60's, where Science! is the solution to, and the cause of, all of life's problems. Don't we all dream of being able to limb into a giant robot, and crush the boss' car underfoot? or tapdance on the local DMV until it is nothing but a pile of rubble? or pick up the entire home office of the IR and throw it into the ocean, then pick up that ocean and throw it into a star, then take that star and throw it into a black hole?

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#30
In reply to #29

Re: Question on available sensor... "metal on metal"

02/12/2016 4:10 PM

That's a perfect description of how John Astin played Dr. Gangrene. So the question we are asking is did the disorder precede the bad sci fi or did the bad sci fi create classic symptoms for the disorder. (chicken or the egg?) If the disorder was first, what real life scientist did the first sci fi writer, to use these traits for his fictional character, emulate? I always thought they were fictional.Very difficult to imagine someone being that way without the sci fi prompting.

I think I can add one more to my list now - Delusions of sanity.

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#31
In reply to #30

Re: Question on available sensor... "metal on metal"

02/12/2016 4:52 PM

I took the SRMD test on the internet - I'm infected. HA HA HA HA HA!

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#36
In reply to #29

Re: Question on available sensor... "metal on metal"

02/15/2016 9:17 AM

"or pick up the entire home office of the IR and throw it into the ocean, then pick up that ocean and throw it into a star, then take that star and throw it into a black hole?"

Pardon my typo, that was supposed to be IRS, not IR. then again, there are so few agencies that would warrant the level of reflexive, instinctual HATE needed for that type of response, that everyone who read it said to themselves, "Nobody would deserve that, except the Tax Man."

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#9

Re: Question on available sensor... "metal on metal"

02/11/2016 3:27 PM

It is difficult to imagine anyone being in an 1800degF environment, never mind falling asleep in it. There are limits on what the human body can withstand.

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#10

Re: Question on available sensor... "metal on metal"

02/11/2016 3:30 PM

Start by describing what the environment looks like, and what is to be achieved, in three or four paragraphs. So far, all the forum knows is that there is a cauldron, a hook, water at 1800degF and a human being that isn't supposed to fall asleep. It is difficult to visualise what the equipment is supposed to be doing, its size, why the cauldron is being lifted, and why the sensor needs to be electrical, etc. After all, 1800degF is above the melting point of most solders used in electrical assembly, for example.

More description and more numbers, please.

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#13
In reply to #10

Re: Question on available sensor... "metal on metal"

02/11/2016 4:43 PM

Sorry for being vague & my english is bad... I was thinking there might be a simple solution, but it seems not. Let me try my best to explain what I'm trying to do.

  • There's 4 "sensored hook" . They will latch themselves onto a cage (hook+cage+load) and lift this load up into a furnace @1800F.
  • It'll then be lower it into water for quenching.
  • Lift it up again & move to the side.
  • Then unhooks itself from the load+cage.
  • Then the operator to retrieve the load and place on another load.

I basically want a way to make sure that this "hook" is always on before the operation begin because I want to prevent human error.

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#14
In reply to #13

Re: Question on available sensor... "metal on metal"

02/11/2016 6:54 PM

I think the best way is to have the cage positioned each time precisely with a positioning jig and to have a separate mechanism for attaching the hooks to the cage....or if the hooks are visible, then cameras positioned to feed video to operator....but this process can be automated.....

http://www.scxspecialprojects.co.uk/Solutions/Specialist-Cranes/Automated-Cranes/

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Anonymous Poster #1
#15
In reply to #14

Re: Question on available sensor... "metal on metal"

02/11/2016 7:27 PM

That's a great idea! That's actually what one of our senior engineer suggested... I completely agree to solving the problem that way, but I just wanted to cover more than one idea..

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#23
In reply to #15

Re: Question on available sensor... "metal on metal"

02/12/2016 10:47 AM

There's a reason the Senior Engineer suggested it: it works, and has withstood the test of time.

If he did not suggest any alternates, then that means that all viable 'alternates' are simply minor variations on the theme.

I can also see why you decided to ask anonymously: you didn't want him to know that you were polling semi-random yahoos, such as us, instead of trusting his judgement and experience. A person does not get the title of Senior Engineer without a few years and hundreds of projects under his belt. Such people need to be respected for the wisdom they bring to the plant, not second-guessed.

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#32
In reply to #14

Re: Question on available sensor... "metal on metal"

02/12/2016 7:51 PM

Actually, you can get safety rated vision systems now that will be able to recognize that the hooks and latches are in the correct position before allowing the (asleep) operator to move on with the sequence. Basically you program the vision system with a series of images of the correct position and it will evaluate the on-line images against that to determine if it's a go / no-go situation. That can be done from a safe enough distance that the cameras are not exposed to the heat. It's done with robotics all the time, no reason it can't work on heavy machinery too.

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#18
In reply to #13

Re: Question on available sensor... "metal on metal"

02/12/2016 4:46 AM

Our crane drivers had no problem locating the hooks on the ladle trunions.

Are yours blind?

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#20
In reply to #18

Re: Question on available sensor... "metal on metal"

02/12/2016 10:05 AM

Huh...? Did I offended you by any chance? What I'm working on is completely different than the picture... I'm just trying to gather ideas and available technology...

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#33
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Re: Question on available sensor... "metal on metal"

02/13/2016 6:34 AM

So what is the load? If you won't say then stop wasting our time!

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#16

Re: Question on available sensor... "metal on metal"

02/12/2016 2:30 AM

Are the hooks themselves exposed to the high temperature for an extended time?

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#21
In reply to #16

Re: Question on available sensor... "metal on metal"

02/12/2016 10:07 AM

Yes, but is there something that would work even if it's not in high temp?

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#28
In reply to #21

Re: Question on available sensor... "metal on metal"

02/12/2016 3:25 PM

Yes! An obvious yes! All other switches in existence! Until you provide pictures... Which Idon't expect.. Im out

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#17

Re: Question on available sensor... "metal on metal"

02/12/2016 4:42 AM

...................

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#26

Re: Question on available sensor... "metal on metal"

02/12/2016 2:44 PM

When you say cauldron, is that what we would call a ladle? I have seen crane-lifted hooks, like you say are to be used, used to lift huge ladles of molten steel. That's a pretty positive latch, because of the built-in spacing of the parts--it is or it ain't! A crane operator can hook these easily by moving the bridge and/or trolley. If you need positive assurance, other than visual, that it is hooked, are there any micro switches that will stand the heat?

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#35
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Re: Question on available sensor... "metal on metal"

02/15/2016 5:18 AM

Precisely my point in #18

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#34

Re: Question on available sensor... "metal on metal"

02/13/2016 11:53 AM

I suggest you investigate the use of fusible links to determine if the operating temperature is within your limits. For example, a silver link would provide a fusing temperature of 1781 f. Alloy links, such as brass, would provide a range of operating temperatures. These links would serve as thermal fuses.

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#37

Re: Question on available sensor... "metal on metal"

02/15/2016 12:38 PM

Basically, at 982 C, everything is emitting light, rather fiercely I might add. You will need optical sensors with attenuating filters/reflectors for when the "cauldron" is in the high temperature environment. These reflectors should also reflect away most of the heat, still allow for robotic camera confirmation of all lift points.

When the cauldron is moved to the quench, the camera(s) would also travel with the crane to the quench, and as the cauldron is lowered into the water, there would have to be gas jets (maybe air, maybe other gas) to keep water/steam from damaging the reflectors, camera lenses. By the time the object has cooled, the reflectors would be pivoted away, allowing direct visual confirmation in the hot water that did not flash off.

The crane interlock confirms all four lift points, and removes the load to the side area. This might actually be more safe than using load cells on the lift points, depending on what extremes the load cells would be subjected to (and destroyed).

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