JP7322825B2 - Module block manufacturing method and furnace construction method - Google Patents

Description

The present invention relates to a module block manufacturing method and a furnace construction method.

Metallurgical coke used in iron making is produced by carbonizing coal in a chamber coke oven. The chamber-type coke oven is configured by alternately arranging a coking chamber and a combustion chamber for supplying heat to the coking chamber in the width direction of the furnace. Heat is supplied from the combustion chamber to the coking chamber through a shaped refractory. Some chamber-type coke ovens have a furnace chamber of 100 gates or more, and such a chamber-type coke oven can be said to be a huge brick structure with a total length of 100 m or more and a height of 10 m or more.

The shaped refractories that make up the coke oven have complex shapes such as rectangles, trapezoids, and L-shapes when viewed from above, unlike bricks for general buildings. Further, the side, top, and bottom surfaces of the standard refractories are sometimes provided with fitting protrusions called dowels for preventing slippage and fitting recesses called tenons for slippage prevention. A coke oven is constructed by combining shaped refractories having such extremely complicated shapes.

Due to the complexity of the shape of the standard refractories, the construction of coke ovens is currently carried out manually by furnace builders. In manual furnace construction, it is necessary to repeat the work of applying mortar to the position where the standard refractories are to be stacked using a tool such as a trowel to achieve a predetermined joint thickness, and then stacking the standard refractories on top of the mortar. There is In doing so, extremely advanced skills are required, such as the need to apply mortar evenly to the surface of a refractory with a complicated shape, but skilled furnace builders with such skills are always in short supply. are doing. Furnace construction work, in which mortar is applied and standard refractories are piled up by hand, can be said to be extremely labor intensive.

For the above reasons, there is a demand for the development of a method for efficiently stacking standard refractories with less manpower.

For example, in Patent Document 1, a module block is manufactured by stacking a plurality of brick layers in which a plurality of bricks are horizontally arranged in a vertical direction in advance at a place other than the construction site of the coke oven, and transported to the construction site. Installation methods have been proposed.

JP 2016-191064 A

In the method proposed in Patent Document 1, since the module blocks are manufactured at a place other than the space-limited coke oven construction site, a sufficient work space can be secured. As a result, in addition to improving work efficiency, it is also easy to automate the stacking of standard refractories and the application of mortar using a robot or the like.

However, as a result of studies by the present inventors, it has been found that the conventional methods such as Patent Document 1 have room for further improvement as described below.

That is, since the shaped refractories used in the construction of coke ovens are produced by firing, there are variations in dimensions. For example, standard refractories generally used have a dimensional error of about 1 to 2 mm in diagonal distance in plan view or side view, and the dimensional error differs for each standard refractory. Therefore, module blocks obtained by piling up standard refractories also have variations in shape for each individual block.

In particular, in a coke oven, coal is introduced into a coking chamber for carbonization, and the obtained coke is pushed out from the side to be discharged, so the walls of the coking chamber are required to have a high degree of flatness. Therefore, when manufacturing module blocks, it is conceivable to adjust the stacking method of the standard refractories so that the wall surface of the coking chamber has the required flatness. cannot be completely eliminated.

Due to this variation in module block shape, there is a problem that the accuracy and work efficiency of coke oven construction are lowered. For example, if the distance between module blocks becomes too small due to variations in shape, the installation accuracy of the module blocks is lowered, and a sufficient thickness of mortar may not be ensured. In particular, if the module blocks interfere with each other, it will be necessary to make adjustments at the site, resulting in reduced work efficiency. Conversely, if the distance between the module blocks becomes too large, the installation accuracy may decrease, and the gaps between the module blocks must be filled with a large amount of mortar. Less efficient.

Therefore, there is a demand for a method of constructing a coke oven using modular blocks, which can construct the coke oven efficiently with higher accuracy. In addition, the construction method using the above module block can be applied to the construction of furnaces other than coke ovens, but even in that case, there is a demand for a method that can construct furnaces with even higher accuracy and efficiency. .

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method for efficiently constructing a furnace with high accuracy by reducing repair work at the furnace construction site.

The gist and configuration of the present invention are as follows.

1. A method for manufacturing modular blocks for use in furnace construction, comprising:
a step of stacking a plurality of standard refractories to form a module block at a location other than the furnace construction site;
a measuring step of measuring contour shapes of the module blocks obtained in the stacking step;
a machining content determination step of determining machining details based on the contour shape measured in the measuring step;
and a processing step of processing the module block by a processing machine based on the processing details determined in the processing content determination step.

2. 2. The module block manufacturing method according to 1 above, wherein the measurement of the contour shape in the measuring step is performed using a three-dimensional measurement method using a laser.

3. 2. The module block manufacturing method according to 1 above, wherein the contour shape in the measuring step is measured by photogrammetry using images of the module block captured from a plurality of viewpoints.

4. 4. The module according to any one of the above 1 to 3, wherein in the processing content determination step, virtual installation is performed to virtually install the module block on a computer, and the processing content is determined based on the result of the virtual installation. Block manufacturing method.

5. A plurality of module blocks having the same shape are produced in the stacking step,
measuring contour shapes of the plurality of module blocks in the measuring step;
Further comprising a module block selection step of performing virtual installation of virtually installing each of the plurality of module blocks on a computer prior to the processing content determination step, and selecting a module block to be used based on the result of the virtual installation. 5. The module block manufacturing method according to any one of 1 to 4 above.

A furnace construction method for constructing a furnace using a plurality of module blocks,
A module block manufacturing process for manufacturing a module block by the module block manufacturing method according to any one of 1 to 5 above;
a module block transporting step of transporting the module blocks manufactured in the module block manufacturing step to the construction site of the furnace;
a mortar application step of applying mortar to a position where the module block is to be installed;
and a module block installation step of installing the module blocks transported in the module block transportation step at the positions where the mortar is applied.

ADVANTAGE OF THE INVENTION According to this invention, the repair work in the construction site of a furnace can be reduced, and a furnace can be built efficiently with high precision.

4 is a flow chart showing a module block manufacturing method according to the first embodiment of the present invention; FIG. 2A is a top view schematically showing an example of the structure of a module block in one embodiment of the present invention; FIG. 2 is a side view schematically showing an example of the structure of a module block in one embodiment of the present invention; FIG. 4 is a top view schematically showing an example of the structure of dowels and tenons between horizontally adjacent standard refractories. FIG. 4 is a side view schematically showing an example of a dowel and tenon structure between vertically adjacent standard refractories. FIG. 4 is a schematic diagram showing an example of the contour shape of one side surface of a module block; FIG. 7 is a schematic diagram showing an example of three-dimensional point cloud data obtained by measuring the contour shape of one side surface of the module block shown in FIG. 6; FIG. 4 is a schematic diagram showing a state in which adjacent module blocks interfere with each other; FIG. 4 is a schematic diagram showing a state in which interference between adjacent module blocks is eliminated by processing; FIG. 4 is a schematic diagram showing an example of a method of evaluating interference between module blocks by virtual installation; FIG. 4 is a schematic diagram showing an example of a method of processing a module block using a processing machine; It is a schematic diagram which shows an example of the method of using the processing machine provided with the sensor. 4 is a flow chart showing a module block manufacturing method according to a second embodiment of the present invention; 3 is a flow chart showing a furnace construction method according to a third embodiment of the present invention;

Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings. It should be noted that the following description exemplifies the embodiments of the present invention, and the present invention is not limited to the following embodiments. In addition, in the following description, unless otherwise specified, the standard refractory and the module block manufactured by stacking the standard refractory are based on the orientation in the state of being incorporated in the coke oven. The terms horizontal, vertical and height are used.

In addition, the "construction" of a furnace in the present invention includes the case of constructing a completely new furnace, the case of constructing a new part additionally to an existing furnace (expansion), and the case of constructing a part of an existing furnace It shall also include the case of constructing a new part to replace the (repair). In other words, "construction" in the present invention includes new installation, extension and repair. For example, in repairing coke ovens in operation, some combustion chambers and carbonization chambers are out of service, and other combustion chambers and carbonization chambers are repaired while they are in operation (hot repair). commonly practiced. The present invention is also applicable to the hot repair.

(First embodiment)
A module block manufacturing method according to a first embodiment of the present invention is a method for manufacturing module blocks used for furnace construction, and includes the following steps as shown in the flow chart of FIG.
・Accumulation process ・Measurement process ・Process to determine processing details ・Processing process

In the following description, the construction of a coke oven will be used as an example to explain the invention, but the invention is also applicable to the construction of furnaces other than coke ovens.

[Stacking process]
In the stacking process, a plurality of standard refractories are stacked to form a module block at a location other than the coke oven construction site. In the present invention, as will be described later, a coke oven can be constructed simply by transporting and installing module blocks manufactured at a location other than the coke oven construction location at the coke oven construction location. It is possible to reduce the work of hand-loading standard refractories one by one by a furnace builder at a bad construction site, and to significantly improve the work efficiency at the construction site.

The above-mentioned "place other than the construction site of the coke oven" is not particularly limited as long as it is a place different from the construction site of the coke oven and where the standard refractory can be stacked to manufacture the module block, and any place. can be used. For example, a place adjacent to a coke oven construction site such as land adjacent to a temporary shed provided at a site for constructing a coke oven, or if the coke oven is to be constructed within a steelworks, within the steelworks The build-up process can be performed elsewhere, such as in the Although it is possible to manufacture the module blocks in a remote location away from the coke oven construction site, considering the time and cost required for transportation, it is preferable to manufacture the module blocks at a location adjacent to the coke oven construction site. Although it is desirable for efficiency to perform the stacking process intensively at one location, it is preferable to perform the stacking process at multiple locations and transport and carry the module blocks manufactured at each location to one coke oven construction site for use. can also

The module block can be a module block for configuring any part of the coke oven, but if a part with a relatively simple structure or a part with a repeated structure is made into a module block, work efficiency can be improved. Great effect. Therefore, in the stacking step, it is preferable to fabricate at least one of the module blocks that form the heat storage chamber and the module blocks that form the combustion chamber.

2 and 3 are schematic diagrams showing an example of a module block in one embodiment of the present invention, showing the structure of the module block that constitutes the combustion chamber of the coke oven. It should be noted that each drawing including FIGS. 2 and 3 simplifies the shape and combination of standard refractories for explanation, and does not show the actual accurate structure.

The module block 1 is configured by stacking a plurality of standard refractories 2, and the individual standard refractories 2 are joined by mortar (not shown) applied to joints between the standard refractories 2. . As described above, the standard refractory 2 for coke ovens has, as shown in FIGS. is provided, and the dowel 3 and the tenon 4 are joined in a fitted state via the mortar 5 .

[[Standard refractories]]
The standard refractories for manufacturing the module blocks are not particularly limited, and any standard refractories such as bricks and precast blocks can be used. Among them, it is preferable to use a normal shaped refractory that is used when constructing a coke oven by hand. By using ordinary standard refractories, it is possible to design the same furnace as the conventional one even when constructing the furnace by the method of the present invention. As a result, at least the same furnace performance as the conventional one is guaranteed. It becomes possible to Also, when using large module bricks, if cracks occur, the cracks may spread throughout the module. Also, the propagation of the crack can be stopped within one standard refractory. The standard refractory referred to here refers to all standard refractories for manual laying, which are not module bricks. is 20 to 40 cm.

[[Manual stacking of standard refractories]]
Stacking of the standard refractories can be performed manually. In the present invention, since module blocks are manufactured at a place other than the coke oven construction site, it is possible to secure a sufficient working space, unlike the case where standard refractories are manually loaded at the coke oven construction site. . Therefore, it is possible to reduce the burden on the worker even if the same manual loading is carried out. In addition, when stacking standard refractories at a coke oven construction site, it is necessary to assemble scaffolds according to the height of the stacked standard refractories and work on them. Since it is necessary to use scaffolding for high-altitude work, it is possible to work on the ground with good footing.

[[Stacking standard refractories by robot]]
Moreover, the stacking of the standard refractories can also be performed using a robot. In this case, part or all of the block manufacturing process can be automated. It becomes possible to automate part or all of the refractory stacking work by robots.

The robot used for stacking the standard refractories is not particularly limited, and any robot can be used. is preferred. An example of the arm-type robot is a vertical articulated robot, which is a type of industrial robot. Also, a module block can be manufactured using an arm-type robot for stacking standard refractories and an arm-type robot for applying mortar.

[[Module block production line]]
It should be noted that regardless of whether manual loading or robots are used, there may be one or more module block manufacturing lines. By stacking standard refractories on multiple lines to manufacture module blocks, it is possible to increase the supply speed of module blocks to the coke oven construction site. is preferably 2 or more, more preferably 3 or more. On the other hand, the upper limit of the number of production lines is not particularly limited, but even if the number of lines is increased more than necessary, the subsequent module block transportation process, mortar coating process and module block installation process at the coke oven construction site will be the rate-limiting processes. Therefore, it becomes difficult to further improve the construction speed of the coke oven, and the cost effectiveness decreases. Therefore, the number of lines should be determined in consideration of the scale of the coke oven, the work speed in each process, and the like.

[Module block size]
The size of the module block is not particularly limited and can be any size. However, when manufacturing module blocks by hand, if the height of the module block is too high, it is necessary to set up a work floor by assembling scaffolding or the like in order to stack the standard refractories at a high position. For example, in Japan, according to the provisions of Article 518 of the Ordinance on Industrial Safety and Health, it is required to provide a work floor when there is a risk of falling when working at a height of 2 m or more. If the height of the module block is less than 2 m, even when manufacturing the module block by hand-loading standard refractories, there is no need to install a scaffold or the like to perform high-place work, resulting in high work efficiency. In addition, when the module block is manufactured using a robot, if the height of the module block is less than 2 m, the height of the position where the standard refractory is stacked is set to the height of the arm of a general arm type robot. It can be within the movable range. Therefore, since module blocks can be manufactured only by moving the robot in the horizontal direction, work efficiency is high. Therefore, from the viewpoint of work efficiency, it is preferable to set the height of the module block to less than 2 m. On the other hand, although the lower limit of the height of the module block is not particularly limited, it is preferable that the module block has two or more layers of standard refractories.

The length of the module block in the longitudinal direction is also not limited, but from the viewpoint of work efficiency, it is preferably 1/8 or more of the furnace length of the coke oven to be constructed. The longitudinal length of the module block may be 1/4 or more of the furnace length of the coke oven to be constructed. On the other hand, the length of the module block in the longitudinal direction is preferably 2/3 or less, more preferably 1/2 or less, of the furnace length of the coke oven to be constructed.

Here, "the length of the module block in the longitudinal direction" refers to the length in the longitudinal direction of the horizontal cross section of the module block, and "the height of the module block" refers to the height from the bottom surface to the top surface of the module block. refers to height. It should be noted that the "longitudinal length of the module block" and the "height of the module block" do not include irregularities such as dowels provided on the side, top and bottom surfaces of the module block. Further, the "furnace length of the coke oven" means the length in the longitudinal direction of each combustion chamber and carbonization chamber that constitute the coke oven. The furnace length of a general coke oven currently in use is about 15 to 17 m.

[Measurement process]
Next, the contour shape of the module block obtained in the stacking process is measured (measurement process). Here, it is assumed that the contour shape also includes information about the dimensions of the module block.

A contour shape measuring method is not particularly limited, and any method can be used. As the measuring method, it is preferable to use a three-dimensional measuring method using a method capable of acquiring three-dimensional contour shape data of the module block, for example, as three-dimensional point cloud data.

For example, in one embodiment of the present invention, the contour shape can be measured using a three-dimensional measurement method using a laser. By irradiating the module block with a scanning laser and measuring the distance from the light source to each point on the surface of the module block by detecting the reflected light, the three-dimensional point cloud data of the contour shape of the module block is obtained. can be obtained. For example, by measuring a module block having a side contour shape shown in FIG. 6, three-dimensional point cloud data of the contour shape shown in FIG. 7 can be obtained. However, the three-dimensional point cloud data in FIG. 7 is obtained by reducing the number of measurement points for the sake of explanation, and in actual measurement, it is preferable to increase the number of measurement points to improve accuracy. Examples of methods that can be used to measure the distance using reflected light include a TOF (Time of Flight) method and a phase difference detection method, but are not limited to these and any method can be used.

The contour shape measurement may be performed on at least one surface of the module block, preferably on a plurality of surfaces, and more preferably on the entire surface.

In another embodiment of the present invention, the contour shape can be measured by photogrammetry using images of the module block taken from a plurality of viewpoints. That is, in photogrammetry, from a plurality of images taken from different viewpoints, the three-dimensional coordinates of the same point in the images can be obtained by the principle of triangulation. Therefore, by obtaining the three-dimensional coordinates of many points in the image, three-dimensional point cloud data of the contour shape of the module block can be obtained.

The dimensional tolerance of the standard refractories that constitute the module block is generally about 1 to 2 mm. Also, the stacking accuracy of the standard refractories in the coke oven is generally required to be about 1 to 2 mm. Therefore, the measurement accuracy of the measuring method used in measuring the contour shape is preferably 2 mm or less, more preferably 1 mm or less. It is also possible to create a three-dimensional polygon model from the obtained three-dimensional point cloud data and use the polygon model in subsequent steps.

[Determining process for processing]
Next, based on the contour shape measured in the measuring step, the content of machining, that is, the shape of the module block to be processed is determined (machining content determination step). The specific form of the processing content is not particularly limited, and generally, the processing content may be determined so that desired processing can be performed by the processing means (processing machine) used in the processing steps described later. The processing content includes, for example, the processing position (part) and processing amount of the module block.

For example, FIG. 8 is a schematic diagram showing a state in which dowels 3 and tenons 4 interfere between adjacent module blocks 1a and 1b. When the dowel 3 and the tenon 4 interfere with each other in this way, the necessary joint thickness cannot be ensured at the interfering portion. Moreover, the installation position of the module block may be displaced due to interference. Therefore, as a result of measuring the contour shape of the module block, if the shape of the dowel or tenon is not appropriate, at least one of the dowel and tenon is processed so as to secure the necessary joint thickness as shown in FIG. should be For example, when processing a dowel, the dowel may be cut to make it smaller, and when processing a tenon, the tenon may be cut and widened. However, if the dowel becomes excessively small, there is a risk that the engagement between the dowel and the tenon will not function sufficiently to prevent displacement, so it is preferable to shave the tenon. In one embodiment of the present invention, in the processing content determination step, if the size of the dowel does not satisfy a predetermined standard due to processing, processing to reduce the processing amount of the dowel (including the case of setting it to zero) may be performed. can. In that case, it is preferable to perform tenon processing instead of dowel processing.

A method for determining the processing content is not particularly limited, and any method can be used. For example, in one embodiment of the present invention, the processing details can be determined by comparing the contour shape measured in the measuring step and the proper contour shape of the predetermined module block. When using this method, it is desirable to prepare in advance information on an appropriate contour shape (three-dimensional shape) of each module block to be manufactured.

Further, in another embodiment of the present invention, it is also possible to perform virtual installation in which the module blocks are virtually installed on a computer, and to determine the processing details based on the results of the virtual installation. This virtual installation will be described below.

FIG. 10 is a diagram schematically showing a method of evaluating interference between module blocks 1 by virtual installation. In the method of the present invention, a coke oven is constructed by transporting and installing the manufactured module blocks to a coke oven construction site. At that time, interference may occur between adjacent module blocks 1 as shown in FIG. Such interference is usually found when the module block is transported to the construction site and is about to be installed. However, by measuring the contour shape of the module block in advance and performing virtual installation on a computer based on the obtained information, it is possible to predict the presence or absence of interference in advance and determine the processing details.

The method of the virtual installation is not particularly limited, and any method can be used. Usually, the data of the contour shape of the module block measured in the measurement process can be used. For example, a plurality of module blocks are manufactured in the stacking process, and the contour shape of each obtained module block is measured in the measuring process. After that, virtual installation is performed using the obtained contour shape data of each module block.

In addition, in the processing content determination process, it is possible to determine whether processing is necessary or not, and if it is determined that processing is unnecessary, the module block can be skipped from the next processing step and proceed to the module block transportation step. be.

[Process]
Next, the module block is processed by a processing machine based on the content determined in the processing content determination step (processing step). By performing processing such as cutting with a processing machine, it is possible to adjust the contour shape of the module block and eliminate interference.

[[Processing machine]]
The processing machine is not particularly limited, and any processing machine can be used as long as it can process the module block. As the processing machine, for example, one or both of a laser processing machine and an end mill can be used. As the end mill, it is particularly preferable to use a ball end mill.

The processing machine preferably comprises position control means for adjusting the processing position. Any position control means can be used. Examples of the position control means include actuators that drive processing means (processing tools such as end mills, laser irradiation means, etc.). The moving means is preferably two-dimensionally movable, and more preferably three-dimensionally movable.

FIG. 11 is a schematic diagram showing an example of a method of processing a module block using a processing machine. The processing machine 10 includes a processing tool 11 for processing module blocks, and the processing tool 11 is configured to be three-dimensionally movable. Specifically, the machining tool 11 is held by the machining head 12 so as to be movable in the Z-axis direction (vertical direction in FIG. 11) by Z-axis direction moving means (not shown). The processing machine 10 further includes a first frame 13 extending in the Y-axis direction (the front-rear direction in the figure) and a second frame 14 extending in the X-axis direction (the left-right direction in FIG. 11). The machining head 12 is held by a second frame 14 so as to be movable in the X-axis direction. The second frame 14 is moved in the Y-axis direction by wheels 16 on rails 15 provided on the first frame 13. set to be drivable.

Then, the module block 1 is subjected to desired machining by driving the machining tool 11 based on the machining details determined in the machining details determining step. For example, when the machining tool 11 is an end mill, the end mill is brought into contact with the position to be machined of the module block 1 to cut a desired amount.

Although FIG. 11 shows an example of a 3-axis machine capable of moving the processing tool 11 along 3 axes, the present invention is not limited to this, and is capable of moving along 4 or more axes (e.g., 4-axis machine, 5 It is also preferable to use a shaft processing machine or the like. If a processing machine capable of moving on four or more axes is used, the module block can be easily processed from multiple directions.

Also, the processing machine preferably further comprises a sensor for measuring the contour shape of at least a portion of the module block. By using the sensor, processing can be performed with higher accuracy. For example, by measuring the contour shape of the module block with the sensor and comparing the obtained data with the data obtained in the previous measurement process, the position and orientation of the module block to be processed can be grasped. can do. It is also possible to set the origin of the processing machine based on the information measured by the sensor.

As the sensor, for example, a distance measuring sensor capable of measuring the distance to the object to be measured can be used. When a distance sensor is used, it is preferable to configure the distance sensor so that it can be scanned at least two-dimensionally. By measuring the distance while two-dimensionally scanning the distance measuring sensor, the contour shape of the module block can be measured. Further, as the sensor, a sensor using a laser irradiation device or an infrared irradiation device similar to that used in the measurement process described above can also be used.

FIG. 12 is a schematic diagram showing an example of a method using a processing machine equipped with sensors. The processing machine 10 shown in FIG. 12 further includes a distance measuring sensor 17 in the processing head 12 in addition to the same configuration as the processing machine 10 shown in FIG. Therefore, by measuring the distance from the distance measuring sensor 17 to the surface of the module block 1 with the distance measuring sensor 17 while scanning the processing head 12 on the XY plane, the contour shape of the upper surface of the module block 1 can be obtained. can be done. Any range sensor can be used as the range sensor without any particular limitation. From the viewpoint of measurement efficiency, it is preferable to use a two-dimensional profile sensor (line sensor) capable of measuring the profile of a line scanned with a laser or the like. If a two-dimensional profile sensor is attached to the processing head and the measurement is performed while the processing head is moved, the contour shape of the upper surface of the module block can be acquired over a wide range.

(Second embodiment)
In the module block manufacturing method according to the second embodiment of the present invention, a plurality of module blocks having the same shape are produced in the stacking step, and the contour shapes of the plurality of module blocks are measured in the measuring step. A module block selection step is further provided. That is, the module block manufacturing method in this embodiment includes the following steps as shown in the flowchart of FIG.
・Accumulation process ・Measurement process ・Module block selection process ・Processing content decision process ・Processing process

The present embodiment will be described below. It should be noted that points that are not particularly mentioned can be the same as those of the above-described first embodiment.

First, in the module block manufacturing method of the present embodiment, a plurality of module blocks having the same shape are produced in the stacking step, and the contour shapes of the plurality of module blocks are measured in the measuring step.

[Module block selection process]
Next, prior to the processing content determination step, virtual installation is performed to virtually install each of the plurality of module blocks on a computer, and a module block selection step is performed to select a module block to be used based on the result of the virtual installation. do. That is, for manufacturing reasons as described above, individual module blocks have variations in shape (including dimensions). Therefore, virtual installation can be performed as described above to select a block having an optimum contour shape for the position where the next module block is to be installed. As a result, it is possible to reduce the amount of processing in subsequent processing steps and improve work efficiency.

The module block selection criteria in the module block selection step are not particularly limited, but it is preferable to select a module block that minimizes the amount of processing or the time required for processing in the subsequent processing steps.

For example, first, virtual installation is performed to calculate the joint thickness d between the module block of interest and the adjacent module block when the module block of interest is installed. This virtual installation is performed for each of the plurality of module blocks, and the joint thickness d _i when each module block is installed is obtained. Then, the module block that minimizes the absolute value |Δd _i | of the difference Δd _i (=d _i −d ₀ ) between the obtained joint thickness value d _i and the predetermined target joint thickness d ₀ is used. It is assumed that In this method, the calculation of |Δd _i | may be performed at least at one location, but |Δd _i | is calculated at a plurality of locations, and the module block is selected so that the sum of |Δd _i | at each location is minimized. is preferred. Although |Δd _i | can be calculated at any position, it is preferable to include positions of dowels and tenons, which are particularly affected by variations. Further, |Δd _i | can be evaluated at two or more, preferably three or more, positions for one dowel and tenon combination.

As a result of selecting the optimum module block in the module block selection process, if it is determined that the module block selected in the next processing content determination process does not require processing, the processing process will be omitted and the module block will be processed. It is also possible to advance to the next module block transportation process.

(Third embodiment)
A furnace construction method according to the third embodiment of the present invention is a coke oven construction method for constructing a furnace using a plurality of module blocks, and includes the following steps as shown in the flow chart of FIG.
・Module block manufacturing process ・Module block transportation process ・Mortar application process
・Module block installation process

[Module block manufacturing process]
In the module block manufacturing process, module blocks are manufactured by the module block manufacturing method described above. The module block can be manufactured, for example, by the module block manufacturing method of the first embodiment or the second embodiment.

[Module block transportation process]
The module blocks manufactured in the module block manufacturing process are then transported to a coke oven construction site. The method of transporting module blocks in the process of transporting module blocks is not particularly limited. Trucks, transporters (self-propelled trolleys), and cranes can be used depending on the distance between the module block manufacturing site and the coke oven construction site. etc. can be used singly or in combination. For example, if there is a temporary shed at the construction site of the coke oven, a transporter is used to transport the module blocks from the location where the module blocks were manufactured and processed to the temporary shed, and an overhead crane and stage jack are used inside the temporary shed. It can be used together and transported to the construction position. In the module block transportation process, the module blocks can be directly transported from the module block manufacturing site to the construction site of the coke oven construction site. According to the progress of the furnace, the module blocks may be transported from the block storage location to the construction position at the coke oven construction site.

[Mortar application process]
Next, mortar is applied to the position where the module block is to be installed. The method of applying mortar is not particularly limited, and mortar is applied to the positions where the bottoms and sides of the module blocks come into contact, in other words, the top and sides where the module blocks are installed, in the same way as when stacking standard refractories. do it.

A spacer can be installed on the mortar-coated surface that contacts the bottom surface of the module block to be installed, ie, the horizontal joint. In some cases, the desired joint thickness cannot be secured due to the load of the module block being applied to this portion. Therefore, by installing a spacer and installing a module block thereon, it becomes possible to easily secure the joint thickness. As the spacer, it is preferable to use a spacer having the same height as the joint thickness.

[Module block installation process]
Next, the module block is installed at the position where the mortar was applied in the mortar application step. The method of installing the module block is not particularly limited, but for example, the module block lifted by a crane or the like may be placed on the surface coated with mortar while adjusting the position. In this way, by constructing in module block units, the burden on workers can be reduced and the standard refractories can be piled up with a high degree of accuracy, compared to the case of manually stacking standard refractories one by one.

A coke oven can be constructed by installing module blocks according to the above procedure. Although the present invention has been described by taking the construction of a coke oven as an example, as described above, the present invention is also applicable to the construction of ovens other than coke ovens.

(Example 1)
According to the process shown in the flow charts of FIGS. 1 and 14, module blocks were manufactured and installed.

Specifically, first, six standard refractories (refractory bricks) were stacked horizontally and five vertically to produce four module blocks (stacking step). Next, the contour shape of the obtained module block was measured using a laser scanner to obtain three-dimensional point group data (measurement step). As the laser scanner, a handy type laser scanner with a measurement accuracy of 0.085 mm was used, and the measurement was carried out over the entire surface of the module block.

Next, the obtained 3D point cloud data and the 3D data of the module block shape prepared in advance as a reference were compared on a computer, and the difference was obtained to quantify the shape error of the module block. As a result, in one of the four module blocks that were manufactured, the difference (error) in the dimension of the tenon on the upper surface of the module block from the standard shape was 3 mm, which was larger than the predetermined standard (here, 2 mm). Do you get it. Therefore, based on the information obtained by comparing the measured contour shape of the module block with the reference module block shape prepared in advance, the details of processing necessary to keep the error within the reference value of 2 mm or less are determined. It was decided (processing content decision process). For the other module blocks, since the difference (error) from the reference shape was 2 mm or less, it was determined that processing was unnecessary.

After that, one module block having a shape deviating from the above reference value was processed by a processing machine according to the processing content determined by the above procedure (processing step). As the processing machine, a ball end mill having three degrees of freedom was used to cut the module block. In the above processing, a laser scanner provided in the laser processing machine was used to measure the contour shape of the module block, and this was used to control the processing machine.

After completing the processing, the processed module blocks were transported to the construction site of the coke oven (module block transportation step), mortar was applied to the position where the module blocks were to be installed (mortar application step), and the module blocks were installed on site. (Module block installation process). Interference between the module blocks at the tenons of the module blocks, which was expected due to deviation from the standard value of the module block shape, did not occur, and it was possible to install efficiently with little correction on site.

(Example 2)
In the processing content determination step, block installation is performed in the same manner as in the first embodiment, except that virtual installation is performed to virtually install the module block on a computer, and the processing content is determined based on the result of the virtual installation. From manufacturing to installation.

Specifically, a plurality of module blocks whose contour shapes were measured in the measurement process were virtually installed on a computer, and the joint thickness was evaluated in that state. Here, the target mortar thickness is 5 mm, the allowable range is ±2 mm with respect to the target mortar thickness, and if the joint thickness is less than 3 mm, which is the lower limit of the allowable range in the virtual installation, it is judged that processing is necessary. and decided on the processing details.

Also in the method of this embodiment, interference between module blocks expected from the deviation of the shape of the module blocks from the reference value did not occur, and the installation could be carried out efficiently with little on-site correction.

<Example 3>
According to the process shown in the flow charts of FIGS. 13 and 14, module blocks were manufactured and installed.

Specifically, first, six standard refractories (refractory bricks) were stacked horizontally and seven vertically to produce 39 module blocks (stacking process). Next, the contour shape of the obtained module block was measured using a laser scanner to obtain three-dimensional point group data (measurement step). As the laser scanner, a handy type laser scanner with a measurement accuracy of 0.085 mm was used, and the measurement was carried out over the entire surface of the module block.

Next, using the obtained three-dimensional point cloud data, virtual installation was performed to virtually install each of the plurality of module blocks on a computer. In the state where the virtual installation is performed, the joint thickness d _i when _each module _block is installed is obtained, and the difference Δd _i (= The absolute value |Δd _i | of d _i −d ₀ ) was calculated. Here, as the joint thickness, the joint thickness at the engagement portion of the dowel and tenon between the target module block and the module block adjacent to the module block is used, and for one set of dowel and tenon, The joint thickness was obtained at three locations. In this embodiment, since there are 56 engagement portions between the dowel and tenon, joint thicknesses are obtained at a total of 168 locations (56×3), and the integrated value of |Δd _i | is determined. (Module block selection step).

For the module blocks selected in the module block selection process, the machining details were determined in the same manner as in the second embodiment, that is, based on the results of the virtual installation (machining details determination process). As a result, there were 14 locations where processing was required, that is, locations where it was determined that the dowel and tenon would interfere. For comparison, when the module block with the maximum integrated value of |Δd _i | That is, by selecting the module block so that the integrated value of |Δd _i | is minimized, the number of machining locations can be reduced to 1/2 or less compared to the case where the maximum module block is used.

After completing the processing, the processed module blocks were transported to the construction site of the coke oven (module block transportation step), mortar was applied to the position where the module blocks were to be installed (mortar application step), and the module blocks were installed on site. (Module block installation process). Interference between the module blocks at the tenons of the module blocks, which was expected due to deviation from the standard value of the module block shape, did not occur, and it was possible to install efficiently with little correction on site.

1: module block 1a, 1b: module block 2: standard refractory 3: dowel 4: tenon 5: mortar 10: processing machine 11: processing tool 12: processing head 13: first frame 14: second frame 15: rail 16 : Wheel 17: Ranging sensor

Claims (6)

A method for manufacturing modular blocks for use in furnace construction, comprising:
a step of stacking a plurality of standard refractories to form a module block at a location other than the furnace construction site;
a measuring step of measuring contour shapes of the module blocks obtained in the stacking step;
a machining content determination step of determining machining details based on the contour shape measured in the measuring step;
and a processing step of cutting and processing the module block with a processing machine based on the processing content determined in the processing content determining step. 2. The module block manufacturing method according to claim 1, wherein the contour shape measurement in said measuring step is performed using a three-dimensional measurement method using a laser. 2. The module block manufacturing method according to claim 1, wherein the contour shape measurement in said measuring step is performed by photogrammetry using images of said module block captured from a plurality of viewpoints. 4. The method according to any one of claims 1 to 3, wherein, in said processing content determination step, virtual installation is performed to virtually install said module block on a computer, and said processing content is determined based on the result of said virtual installation. module block manufacturing method. A plurality of module blocks having the same shape are produced in the stacking step,
measuring contour shapes of the plurality of module blocks in the measuring step;
Further comprising a module block selection step of performing virtual installation of virtually installing each of the plurality of module blocks on a computer prior to the processing content determination step, and selecting a module block to be used based on the result of the virtual installation. The module block manufacturing method according to any one of claims 1 to 4. A furnace construction method for constructing a furnace using a plurality of module blocks,
a module block manufacturing process for manufacturing a module block by the module block manufacturing method according to any one of claims 1 to 5;
a module block transporting step of transporting the module blocks manufactured in the module block manufacturing step to the construction site of the furnace;
a mortar application step of applying mortar to a position where the module block is to be installed;
and a module block installation step of installing the module blocks transported in the module block transportation step at the positions where the mortar is applied.

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