CN115943003A

CN115943003A - Detecting metal separated from casting mold

Info

Publication number: CN115943003A
Application number: CN202180049542.6A
Authority: CN
Inventors: J·R·B·麦卡勒姆; R·B·瓦格斯塔夫; M·R·科斯米奇; W·J·芬顿
Original assignee: Novelis Inc Canada
Current assignee: Novelis Inc Canada
Priority date: 2020-07-23
Filing date: 2021-07-23
Publication date: 2023-04-07
Also published as: US20230241668A1; DE212021000423U1; MX2023000876A; EP4185421A1; BR112022023134A2; CA3189638A1; KR20230009951A; JP2023535435A; WO2022020717A1

Abstract

During the casting process, the metal can be separated from the casting mold. A detection system is capable of monitoring the mold and determining whether the metal has separated from the mold. The detection system can include a camera, a light source, and a computer system. The camera and the light source can be placed on opposite sides of the casting mold and positioned so as to both be directed toward the mold. The computer system is capable of detecting whether there is any visible light between the mold and the metal based on data received from the camera. The computer system can then determine that the metal has been pulled away from the mold based on the detected light.

Description

Detecting metal separated from casting mold

Cross Reference to Related Applications

The benefit and priority of U.S. provisional application nos. 62/705,945 entitled "detecting metal separated from casting mold" filed on 23/7/2020 and 62/705,947 entitled "monitoring casting environment" filed on 23/7/2020, the contents of both of which are hereby incorporated by reference in their entirety for all purposes.

Technical Field

The present disclosure relates generally to metal casting and, more particularly, to related processes and systems for monitoring a metal casting process.

Background

Molten metal may be deposited into a mold to produce a metal ingot. These ingots may be formed using, for example, direct Chill (DC) casting or electromagnetic casting (EMC). In DC casting, molten metal is typically poured into shallow water-cooled molds. The mold may include a bottom block mounted on a telescoping hydraulic table to form a false bottom. The bottom block may be positioned at or near the bottom of the mold prior to the molten metal being deposited into the mold. As the molten metal is deposited into the mold, the molten metal may fill the mold cavity and the outer and lower portions of the mold may be cooled. The molten metal may cool and begin to solidify, forming a shell of solid or semi-solid metal around the molten core. As the bottom block is lowered, additional molten metal may be fed into the mold cavity.

During solidification, the cooling metal may shrink and come off the mold walls, leaving gaps. As additional molten metal is fed into the mold cavity, newly added molten metal may flow through the gap between the mold wall and the ingot shell and down the exterior of the ingot. If the molten metal contacts and/or traps the cooling liquid, an explosion may result. In addition, if the molten metal solidifies in the gap, it may cause the ingot to jam in the mold as the bottom block continues to be lowered, leaving a space between the bottom of the ingot and the bottom block. Eventually, the weight of the ingot may cause the ingot to fall from the mold onto the lowered bottom block, causing molten metal to splash from the mold into the casting environment.

To reduce the risks associated with the gap between the ingot and the mold, an operator may look at the edges of the mold during casting to find such a gap, either personally or through a video monitoring system. However, the operator may miss or ignore the gap because the gap is small or difficult to see. In addition, several molds may be used simultaneously, requiring an operator to distract between the molds, or multiple operators to monitor the various molds.

Disclosure of Invention

The terms embodiment and similar terms are intended to refer broadly to all subject matter of the present disclosure and appended claims. Statements containing these terms should not be understood to limit the subject matter described herein or to limit the meaning or scope of the claims appended hereto. Embodiments of the present disclosure encompassed herein are defined by the following claims, not this summary. This summary is a high-level overview of aspects of the disclosure and introduces some concepts that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to the entire specification of the disclosure, any or all of the drawings, and appropriate portions of each claim.

Certain examples herein present systems and methods for detecting metal separated from a casting mold during a casting process. Various examples utilize one or more molds to contain molten and/or solidified metal during the casting process. At least one of the molds may have a plurality of sidewalls spanning between the top and bottom of the mold. The top and bottom of the mold may be open, allowing molten metal to be deposited through the open top and allowing solidified metal to exit through the open bottom. The system may include one or more cameras, wherein a field of view of at least one camera includes at least a portion of the mold. For example, the field of view of the one or more cameras may include the top of the mold. The light source may be positioned adjacent to the mold, for example on a side of the mold opposite the one or more cameras. The light source may be positioned to direct light toward the mold. For example, the light source may be positioned to illuminate light from the bottom of the mold to a camera at the top of the mold. Based on the image data received from the camera, the computer system may be used to detect whether light is visible between the solidified metal in the mold and the sidewall of the mold. The computer system may determine whether the metal in the mold has separated from the sidewall of the mold, for example, based on whether the system has detected optical visibility between the solidified metal in the mold and the sidewall of the mold.

In various examples, a system for detecting an unexpected gap between solidified metal and a mold sidewall is provided. The system may include a mold, a camera, a light source, a processor, and a memory. The mold may have a first side, a second side opposite the first side, and a plurality of walls spanning between the first side and the second side. The camera may be positioned adjacent to the first side of the mold and have a field of view that includes the first side of the mold. The light source may be positioned adjacent to and directed toward the second side of the mold such that when the solidified metal has separated from at least one of the mold walls, light from the light source may be visible to the camera through the first side of the mold. The memory may include instructions that, when executed by the processor, may cause the system to detect light between the mold sidewall and the solidified metal based at least in part on the data from the camera, and determine whether separation of the mold sidewall and the solidified metal has occurred based at least in part on the detected light.

In various examples, a computer-implemented method for detecting solidified metal separated from a mold is provided. The method can include receiving molten metal into a mold having two opposing faces and a plurality of sidewalls spanning between the two opposing faces. The mold may have at least one sidewall that contacts the molten metal as it cools and solidifies. Light between the at least one sidewall of the mold and the solidified metal may be detected based at least on data received from a camera having a field of view of at least a portion of the first face of the mold. The light source can be positioned adjacent to and direct light toward the second side of the mold. The method may further include determining whether the solidified metal has pulled away from the sidewall of the mold based on the detected light.

In various examples, a system for detecting metal separated from a casting mold is provided. The system may include a mold, a runner, a camera, an optical, and a computer system. The mold can receive and contain metal. The mold may have a first side, a second side opposite the first side, and a plurality of sidewalls spanning between the first side and the second side. The launder is positionable above the mould and includes a channel for receiving molten metal and one or more openings for transferring the molten metal from the launder to the mould. The camera may have a field of view that includes the first side of the mold. The light may be positioned adjacent to the second side of the mold and may direct the light toward the second side of the mold. When the solidified metal is separated from the at least one mold wall, light may be visible to the camera through the first side of the mold. The computer system may include one or more processors, memory, and computer-executable instructions stored in the memory and executable by the one or more processors. The computer-executable instructions may cause the computer system to detect whether light is visible between the mold sidewall and the solidified metal based at least in part on data from the camera, determine whether separation of the mold sidewall from the solidified metal has occurred based at least in part on the detected light, and regulate flow of molten metal from the channel to the mold.

In various examples, a system for detecting metal separated from a mold is provided. The system may include a mold configured to receive and contain the metal, the mold including a first side, a second side opposite the first side, and a plurality of walls spanning between the first side and the second side; a container positioned above the mold, the container having a bottom and defining a channel for containing the metal, the bottom of the container defining one or more apertures for flow of the metal from the container to the mold; a camera having a field of view including at least a portion of the first side of the mold; and light positioned adjacent the second side of the mold for directing light toward the second side of the mold, the light being visible through the first side of the mold to the camera when the metal is separated from at least one of the plurality of sidewalls. The system may detect whether light between at least one of the plurality of sidewalls and the metal is visible based at least in part on data from the camera, determine whether separation between at least one of the plurality of sidewalls and the metal has occurred based at least in part on whether light between at least one of the plurality of sidewalls and the metal is detected to be visible, and regulate the flow of the metal from the container to the mold based at least in part on determining whether separation of at least one of the plurality of walls and the metal has occurred.

Other objects and advantages will become apparent from the following detailed description of non-limiting examples.

Drawings

The specification makes reference to the following drawings, wherein the use of the same reference symbols in different drawings is intended to indicate the same or similar components.

Fig. 1 is a cross-sectional side view of a system for detecting solidified metal separated from a mold, in accordance with various embodiments.

Fig. 2 is a front view of the system of fig. 1 including a plurality of molds, according to various embodiments.

Fig. 3 is a top view of the mold of fig. 1 after molten metal has been added to the mold and begins to solidify and pull away from the mold sidewalls, according to various embodiments.

Fig. 4 is a flow diagram illustrating a process of detecting whether a solidified metal has been separated from a mold, for example, by using the systems of fig. 1-3, according to various embodiments.

Fig. 5 illustrates the example computer system of fig. 1 and 2, according to various embodiments.

Detailed Description

The terms "invention," "this invention," "the invention," and "the invention" as used herein are intended to refer broadly to all subject matter of this patent application and the appended claims. Statements containing these terms should not be understood to limit the subject matter described herein or to limit the meaning or scope of the appended patent claims. The subject matter of embodiments of the present invention is described with specificity herein to meet statutory requirements, but such description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other present or future technologies. This description should not be construed as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangements of elements is explicitly described. As used herein, the meaning of "a/an" and "the" includes singular and plural referents unless the context clearly dictates otherwise.

While certain aspects of the present disclosure may be applicable to any type of material, such as metal, certain aspects of the present disclosure may be particularly applicable to aluminum.

All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of "1 to 10" should be considered to include any and all subranges between (and including 1 and 10) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more (e.g., 1 to 6.1) and ending with a maximum value of 10 or less (e.g., 5.5 to 10).

The following examples will serve to further illustrate the invention but at the same time do not constitute any limitation of the invention. On the contrary, it is to be clearly understood that resort may be had to various embodiments, modifications, and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the present invention.

Fig. 1 and 2 depict an inspection system 100 for inspecting solidified metal 114 separated from at least one sidewall and associated components of a mold 120, according to certain embodiments. The detection system 100 may include any number of components, however, in various embodiments, the detection system 100 includes an ingot 110, a mold 120, a camera 140, a light source 150, and a computer system 160. As depicted in fig. 1 and 2, detection system 100 is depicted as further comprising flow cell 130, however, detection system 100 may include additional or alternative components.

The ingot 110 may include molten metal 112 and solidified metal 114. In various examples, the solidified metal 114 is molten metal 112 that has contacted the walls of the mold 120 and cooled. In the illustrative example, the molten metal 112 is deposited into the mold 120 and begins to solidify, forming the solidified metal 114. The bottom block 122 of the mold 120 may be stably lowered as the molten metal 112 is added to the top of the mold 120. The addition of molten metal 112 may create a pocket of molten metal 112 surrounded by walls of solidified metal 114 and continuously elongate the ingot 110.

Ingot 110 may be formed of any metal or combination of metals capable of being heated to a melting temperature. In a non-limiting example, the metal used to form the ingot 110 includes aluminum. Additionally or alternatively, the metal used to form the ingot 110 may include iron, magnesium, or a combination of metals.

One or more molds 120 (hereinafter individually or collectively referred to as "molds") may be provided as part of the inspection system 100. The mold 120 may receive the molten metal 112 into one or more mold openings. The molten metal 112 may be received by the mold 120 and formed into a shape by the mold as the molten metal 112 cools and becomes the solidified metal 114. The solidified metal 114 (e.g., once cooled) may exit the die 120 through one or more die outlets. In various embodiments, the mold 120 may be rectangular, having four sidewalls, an open top for receiving the molten metal 112, and an open bottom through which the solidified metal 114 may exit. The mold 120 may additionally or alternatively have or cooperate with a bottom block 122 for forming the ingot 110, such as may typically be the case in a mold 120 used in direct chill casting. The bottom block 122 may be movable or fixed. In some embodiments, the bottom block 122 may be a dummy head mounted on a telescoping hydraulic table. In alternate embodiments, the mold 120 may be of any type and shape suitable for casting the molten metal 112.

The mold 120 may additionally or alternatively help cool the molten metal 112 to form the solidified metal 114. In a non-limiting example, the mold 120 is a water-cooled mold. However, the mold 120 may have heated walls to delay mold wall cooling (e.g., an Ohno Continuous Casting (OCC) mold). The mold 120 may also be or include a cooling system using one or more of air, ethylene glycol, or any suitable cooling medium.

The molten metal 112 may be deposited through one or more launders 130 positioned adjacent to the mold 120. The launder 130 may include one or more openings for distributing the molten metal 112 into the mold 120. In various embodiments, the launder 130 may be positioned above the mold 120 and deposit the molten metal 112 into the mold 120 from one or more openings. The launder 130 may be any size and shape suitable for receiving and distributing the molten metal 112. As depicted, the launder 130 has a rectangular shape with a U-shaped channel for receiving the molten metal 112.

Spout 130 may also include a flow control device 132. The flow control device 132 may control the flow rate of the molten metal 112 from the launder 130 to the mold 120. As an illustrative example, flow control device 132 may include a pin 134. Pin 134 may be positioned in an opening 136 in runner 130. The opening 136 and/or the pin 134 may be tapered such that moving the pin downward relative to the opening causes the annular space between the pin and the opening to become smaller. The pin 134 can be raised and/or lowered to regulate the flow of the molten metal 112 out of the launder 130. For example, the pin 134 may be raised to enlarge the annular space between the pin and the opening 136, thereby increasing the molten metal 112 (e.g., as shown in solid lines) flowing out of the launder 130. Further, the pin 134 may be lowered to constrict the annular space between the pin and the opening 136, thereby reducing and/or stopping the flow of the molten metal 112 out of the launder 130 (e.g., as shown in phantom).

Computer system 160 may automatically raise and/or lower pin 134. For example, the pins 134 may be automatically raised and/or lowered to maintain the level of molten metal 112 in the mold 120 within a set point range. In response to detecting that the size of the gap 116 is within a certain range, the pin 134 may additionally or alternatively be automatically raised and/or lowered. However, the pin 134 may be manually raised and/or lowered. In some examples, manual raising and/or lowering of pin 134 may be prompted by computer system 160. In various embodiments, the pins 134 may be raised and lowered at timed intervals (e.g., the pins may be pulsed) to regulate the flow of molten metal 112 into the mold 120. Pulsing the pins 134 may cause the molten metal 112 to flow into the mold 120 to break the surface tension of the molten metal in the mold 120. Disrupting the surface tension of the molten metal 112 in the mold 120 may make it easier for the molten metal to flow along the surface of the molten metal in the mold, such as into the gap 116. In further embodiments, the flow control device 132 may additionally or alternatively include a valve, a stopper, a funnel, or other suitable structure.

The detection system 100 may also include one or more cameras 140 capable of capturing still or moving images. The camera 140 may be positioned facing the mold 120 or otherwise have a field of view 142 that includes at least a portion of the mold 120. In various implementations, the camera 140 is positioned above the mold 120, with the field of view 142 including at least a portion of the top of the mold 120. The camera 140 may additionally or alternatively be positioned below the mold 120, wherein the field of view includes at least a portion of the bottom of the mold 120. In various implementations, the camera 140 is movable and/or has a varying field of view 142.

The detection system 100 may include a plurality of cameras 140 working in concert. Multiple cameras 140 may be positioned to have adjacent or overlapping fields of view 142. For example, two cameras 140 may be mounted at different heights above the mold 120 and may have overlapping fields of view 142 of the top of the mold 120. As another example, two cameras 140 may be mounted such that each camera 140 has a field of view 142 of a portion of one side of the mold 120. Each field of view 142 may be combined to form an image of the entire side of mold 120 or other focused region of interest.

The light source 150 may be positioned on the opposite side of the mold 120 from the camera 140. As further described below in discussing fig. 3, the light source 150 may be positioned to emit light directly toward the mold 120 such that if there is a gap 116 between at least one sidewall of the mold 120 and the solidified metal 114 (as shown, the size of the gap 116 is exaggerated for ease of viewing), the emitted light will shine through the gap 116. In a non-limiting example, the camera 140 is positioned above the mold 120 and the light source 150 is positioned below the mold 120 to emit light directed upward. The light source 150 may alternatively be positioned above the mold 120 to emit light directed downward, and the camera 140 positioned below the mold 120. In further examples, the light and camera may be positioned on the same side of the mold. If present, the emitted light visible through the gap 116 may be captured, recorded, and/or detected by the camera 140. The emitted light may be or include light that has traveled indirectly and is bounced, reflected, and/or refracted when traveling from the light source 150 through the gap 116 to the camera 140. For example, light may reflect from the solidified metal 114 and/or the mold 120 as it travels through the gap 116. However, the light may be or include light that travels directly from the light source 150 through the gap 116 and to the camera 140 with little or no reflection or refraction.

The light source 150 may emit a single color of light or be capable of changing between multiple colors. The color may be in the visible spectrum or in the infrared spectrum. In a non-limiting example, the light source 150 includes an LED capable of changing color. The light source 150 may include, alone or in combination, incandescent, compact fluorescent, halogen, metal halide, light Emitting Diode (LED), fluorescent tube, neon, high intensity discharge, or other light emitter. Further, the light source 150 may emit light directly and correspond to a component capable of generating light, and/or may additionally or alternatively emit light indirectly and include one or more reflective surfaces or other elements capable of reflecting or directing light to a target focal region. Further non-limiting examples include mirrors or fiber optic cables for directing light.

The detection system 100 may include a computer system 160. Computer system 160 may include hardware and software for executing computer-executable instructions. For example, computer system 160 may include a memory, a processor, and an operating system for executing computer-executable instructions (fig. 5). The computer system 160 may have hardware or software that is capable of communicating with other devices through a wired connection or a wireless connection (e.g., bluetooth). The computer system 160 may communicate with one, some combination, or all of the following devices: flow control device 132, camera 140, light source 150, alarm 170 (fig. 2), or sensor 180 (fig. 2).

In an embodiment, computer system 160 is located in a single physical location. For example, the computer system 160 may be hardware and software located in the same manufacturing facility as the mold 120 and communicating with the camera 140 and/or the light source 150 over a local communication network (e.g., wi-Fi or bluetooth). Additionally or alternatively, the plurality of computer systems 160 may be in communication with the camera 140 and/or the light source 150 and/or located in a plurality of physical locations. For example, computer system 160 may be a cloud computing system including any number of internet-connected computing components.

The computer system 160 may include hardware and software capable of performing the following steps: receiving data from the camera 140, analyzing the received data to detect light between the mold 120 and the solidified metal 114, and determining whether the metal 114 has separated from the mold 120. Some or all of these steps may be performed by a single computer system 160 or multiple computer systems.

The detection system 100 as depicted in fig. 2 includes additional elements of an alarm 170 and a sensor 180. However, the detection system 100 of fig. 2 may include additional or alternative elements.

The computer system 160 may alert the user after having determined that the solidified metal 114 has separated from the mold 120 (e.g., there is a gap between the mold 120 and the solidified metal 114, such as gap 116, such that light from the light source 150 is detected by the camera 140). The computer system 160 may also communicate with an alarm 170. For example, the computer system 160 may activate the alarm 170 in response to a determination (e.g., made by the computer system 160) that a gap 116 exists between one or more sidewalls of the mold 120 and the solidified metal 114, such as when the camera 140 captures, records, and/or detects light passing through the gap 116. The alarm 170 may correspond to or include a bell, a light, an alarm, a display, a speaker, or any other object capable of drawing the attention of a user and/or conveying information to the user.

Other actions may be prompted in addition to or instead of activating the alarm 170. In various embodiments, the change in the flow of molten metal 112 into the mold 120 may be introduced in conjunction with or in lieu of activation of the alarm 170. For example, the flow control device 132 may be controlled to increase, decrease, or otherwise change the flow rate, amount, or other characteristic of the molten metal 112 flowing into the mold 120. In various embodiments, the warning may additionally or alternatively be displayed, recorded, sent, or otherwise communicated to a user or another aspect of the system (e.g., and may be performed independently of or in conjunction with activating the alarm 170 and/or altering the flow of the molten metal 112).

In various embodiments, the light source 150 may utilize light of a color that is different from other colors present in the environment of the detection system 100. The sensor 180 may facilitate this function. Sensor 180 may detect light in the surrounding manufacturing environment and communicate this data to computer system 160. In a non-limiting example, the ambient environment contains red light. Sensor 180 detects the red light and sends the data to computer system 160. Based on this data, computer system 160 sends signals to light source 150 to produce a green color and/or a light color other than red. In various embodiments, the light source 150 may be tuned by a technician during setup to produce a light color that is different from the color of other light and/or other objects in the relevant ambient environment (such as the environment surrounding the mold 120), which may affect the color that will appear in the field of view of the camera 140, and may otherwise negatively affect the ability of the camera 140 to collect light that may be differentiated to determine the presence of the gap 116 between the solidified metal 114 and the sides of the mold 120. Additionally or alternatively, in some embodiments, ambient light and/or colors or types of light that may be present in the surrounding manufacturing environment may be detected by the sensor 180 or other suitable input and filtered out by the computer system 160, for example, to facilitate detection of the associated emitted light to determine the presence of the gap 116.

As depicted in fig. 2, the inspection system 100 may include a plurality of

molds

120A, 120B, 120C. The plurality of

molds

120A, 120B, 120C may be positioned to receive the molten metal 112 from the launder 130. The plurality of

molds

120A, 120B, 120C can alternatively receive the molten metal 112 from a plurality of launders 130. The

multiple molds

120A, 120B, 120C may all receive the same type, alloy, and/or combination of molten metal 112, however, each

mold

120A, 120B, 120C may receive a different type, alloy, and/or combination of molten metal.

In various embodiments, one or more cameras 140 and/or one or more light sources 150 are positioned around the plurality of

molds

120A, 120B, 120C. For example, two cameras 140 may be positioned to have overlapping fields of view 142 that include at least a portion of the first mold 120A. The additional camera 140 may be positioned to have a field of view 142 that includes at least a portion of the first mold 120A and the second mold 120B. The movable camera 140 may additionally be positioned to have a field of view 142 that includes at least a portion of the third mold 120C. The one or more light sources 150 may be positioned on the opposite side of the plurality of

molds

120A, 120B, 120C from the one or more cameras 140.

Turning to fig. 3, an example of the field of view 142 of the camera 140 of fig. 1 and 2 is depicted. The field of view 142 may include the mold 120, the molten metal 112, and the solidified metal 114. The field of view 142 may also include a gap 116 (if present) between at least one sidewall of the mold 120 and light 152 (e.g., from a light source 150) illuminated through the gap 116. As depicted, the field of view 142 includes a side (e.g., a top side) of the mold 120 and an entire perimeter of the mold 120. However, the field of view 142 may include a sub-portion of the perimeter of the mold 120, portions of multiple molds (e.g.,

molds

120A, 120B, and 120C), multiple sides of the mold 120, or multiple sides of

multiple molds

120A, 120B, and 120C.

For example, the field of view 142 is depicted as being divided into four quadrants (e.g., I, II, III, IV). However, the field of view 142 may include more or fewer quadrants. A single camera 140 may have a field of view 142 that includes all four quadrants. However, a single camera 140 may have a field of view 142 corresponding to a single quadrant. Additionally or alternatively, a single camera 140 may have a field of view 142 corresponding to a quadrant combination. In some implementations, a single camera 140 may have multiple fields of view 142 (e.g., each quadrant is a different field of view 142) between which the camera 140 may switch. For example, the movable camera 140 may switch between views 142 as the camera 140 translates around the top of the mold 120.

In various embodiments, the quadrants may include markers corresponding to the coordinates of the locations on the ingot 110 and/or mold 120. In some embodiments, the computer system 160 may determine that the gap 116 exists and then use the coordinates to determine the location of the gap 116.

Fig. 4 is a flow diagram representing an example of a process 400 for identifying a gap 116 between a sidewall of a mold 120 and a solidified metal 114 using the detection system 100, according to some embodiments. Some or all of process 400 (or any other process, or variations and/or combinations thereof, described herein) may be carried out under the control of one or more computer systems configured with executable instructions, and may be implemented as code (e.g., executable instructions, one or more computer programs, or one or more application programs) collectively executed on one or more processors, by hardware, or combinations thereof. The code may be stored on a computer-readable storage medium in the form of a computer program, for example, comprising a plurality of instructions executable by one or more processors. The computer readable storage medium may be non-transitory. Further, unless otherwise indicated, the acts illustrated in the processes need not be performed in the order illustrated, and/or some acts may be omitted in the embodiments.

Process 400 may include, at 402, depositing a metal (such as molten metal 112) into one or more molds (such as mold 120). The molten metal 112 may be deposited into the mold 120 through a launder 130 as described herein. Launder 130 may deposit molten metal 112 into mold 120 through one or more openings in launder 130. The amount or flow rate of the molten metal 112 entering the die 120 may be regulated by controlling the flow control device 132. The molten metal 112 may enter the mold 120 through one or more openings in the mold 120. The molten metal 112 received by the mold 120 may contact one or all of the sidewalls of the mold 120. The temperature of the molten metal 112 may decrease after entering the mold 120, and the molten metal 112 may cool and become the solidified metal 114. The solidified metal 114 may contract away from the sidewalls of the mold 120, resulting in one or more gaps 116 being formed between the solidified metal 114 and the sidewalls of the mold 120.

Process 400 may include, at 403, emitting light (such as light 152) from a light source (such as light source 150 described above). The light sources 150 may be positioned on opposite sides of the mold 120 and oriented to emit light 152 toward a lens of a camera, such as camera 140. The solidified metal 114 in the mold 120 may block the emitted light 152 if the solidified metal 114 contacts all sides of the mold 120. However, if there is a gap (such as gap 116) between the solidified metal 114 and the mold 120, the emitted light may travel through the gap 116 and be observed by the camera 140. The light source 150 may emit light 152 comprising a plurality of colors. For example, the light source 150 may emit light of a particular color that is different from the color of light visible in the surrounding environment. In some embodiments, the sensor 180 is used to detect a light source in the ambient environment. In some cases, the sensor 180 sends the detected light data to a computer, such as the computer system 160, which sends instructions to the light source 150 to illuminate the light 152 with a color different from the color of the detected light.

The process 400 may include detecting light between the sidewall of the mold 120 and the solidified metal 114 at 404. The detected light may be light 152 emitted by the light source 150. In some embodiments, the detected light 152 is ambient light in the ambient environment. The light 152 may be detected after traveling through the gap 116 between the mold 120 and the solidified metal 114. The camera 140 may view the light through the gap 116. The camera 140 may then send data to the computer system 160 indicating that the light between the mold 120 and the solidified metal 114 is visible. The computer system 160 may process the data and determine that light has been detected between the sidewall of the mold 120 and the solidified metal 114.

The process 400 may include determining that the solidified metal 114 has been separated from the mold 120 at 406. The computer system 160 determines that the solidified metal 114 has separated from the mold 120 by determining whether light 152 has been detected between the sidewall of the mold 120 and the solidified metal 114. In some implementations, the computer system 160 can process the data received from the camera 140 to determine whether the solidified metal 114 has separated from at least one sidewall of the mold 120. The computer system 160 may process the data and determine whether the visual data includes light 152 between the mold 120 and the solidified metal 114. If light 152 is present between the mold 120 and the solidified metal 114, the computer system 160 may determine that the solidified metal 114 has pulled away from the sidewalls of the mold 120. In an illustrative example, the computer system 160 receives visual data from the camera 140 and processes the data using a machine vision application. The machine vision application analyzes the visual data to determine whether the lights 152 are visible and/or whether certain defined conditions exist in the visual data. The machine vision application may then send this data to another application and/or determine that the solidified metal 114 has pulled away from the sidewalls of the mold 120.

The computer system 160 may use additional or alternative data received from the camera 140 to determine that the solidified metal 114 has been pulled away from the mold 120. In some embodiments, the computer system 160 may receive information about the mold 120 and/or the solidified metal 114 from a data source (e.g., a database) to help determine whether the solidified metal 114 has been separated from the mold 120. In the illustrative example, the first mold 120A and the second mold 120B are monitored by the camera 140. The computer system 160 receives information that the solidified metal 114 in the first mold 120A is more likely to separate from the first mold 120A than the solidified metal 114 in the second mold 120B (e.g., the first mold 120A may be located in a region closer to a cooling source than the second mold 120B, resulting in the solidified metal 114 in the first mold being more likely to cool and shrink away from the walls of the first mold 120A faster). In response to the received information, the computer system 160 instructs the camera 140 to maintain more of the first mold 120A in the field of view 142 of the camera 140.

The process 400 may include, at 408, responding to a determination by the computer system 160 that the solidified metal 114 has separated from the sidewall of the mold 120. The response may include sending an alert to the user. A warning may be sent by the computer system 160 to the user to inform them that the solidified metal 114 is separated from the mold 120. For example, the warning may be to activate an alarm, such as alarm 170 described above, and alert the user that detachment has occurred. The alert may also or alternatively be a message, visual indication, or audio indication that draws the attention of the user and/or notifies them of the detachment.

The computer system 160 may additionally or alternatively respond to separation of the solidified metal 114 from the mold 120 by varying the flow rate of the molten metal 112 into the mold 120. As the molten metal 112 is deposited into the mold 120, it may flow into the gap 116 caused by the shrinkage of the solidified metal 114 away from the mold. The gap 116 may be small, for example, such that molten metal 112 may be added to the mold 120 to fill the gap. In contrast, the gap 116 may be large, e.g., such that the molten metal 112 may be added to the mold 120, flow through the gap 116, and exit the bottom of the mold 120. In some embodiments, the molten metal 112 flowing through the gap 116 may contact water and/or a cooling solution, which may cause an explosion. Thus, the computer system 160 may determine the size of the gap 116 and use this information to determine whether to change the flow rate in response to the gap 116.

In various embodiments, the gap 116 may be filled by regulating the flow of the molten metal 112 into the mold 120. For example, the flow rate of the molten metal 112 into the mold 120 may be adjusted with the flow control device 132. In response to the computer system 160 detecting the gap 116 (and/or detecting that the gap 116 is small enough to allow filling), the flow of the molten metal 112 into the mold 120 may be increased, for example, by raising the pins and increasing the flow rate of the molten metal through the openings in the launder 130. Additionally or alternatively, the height of the pins may be pulsed to vary the flow rate of the molten metal 112 into the mold 120. The increased and/or varied flow rate of the molten metal 112 may cause the molten metal 112 to flow into the gap 116. The molten metal 112 may cool and become solidified metal 114. The solidified metal 114 may substantially or completely fill the gap 116. The filled gap 116 may prevent or prevent additional molten metal 112 from flowing through the gap. If the gap 116 is large, the computer system 160 may send instructions to the flow control device 132 to reduce or stop the flow of molten metal 112 into the mold 120. The computer system 160 may also prompt or cause a change in the flow rate by sending instructions to the user.

In some embodiments, the process 400 includes steps 410-414 for separating the mold 120 in response to the solidified metal 114. The process 400 may include, at 410, determining a size of the gap 116 between the solidified metal 114 and the mold 120. In various examples, the computer system 160 receives data from the camera 140 that includes or includes the amount of light 152 captured by the camera 140 in the gap 116 between the solidified metal 114 and the mold 120. The computer then uses the amount of light 152 detected in the received data to determine the size of the gap 116.

The process 400 may include, at 412, comparing the size of the gap 116 between the solidified metal 114 and the mold 120 to a threshold. The threshold may be received by the computer system 160 and may be based on at least the type of ingot 110 being formed, the type of mold 120, and/or other characteristics of the detection system 100. The process 400 may include increasing or decreasing the flow of the molten metal 112 into the mold 120 based on the comparison of the gap 116 to the threshold value at 414. For example, if the gap 116 is below a threshold, the flow of molten metal 112 into the mold 120 may increase. Additionally or alternatively, if the gap 116 is greater than a threshold value, the flow of molten metal 112 into the mold 120 may be reduced and/or stopped.

FIG. 5 is an example computer system 500 for use with the system for detecting solidified metal 114 separated from a mold 120 as shown in FIG. 1. In some embodiments, the computer system 500 performs one, some, or all of the steps of the process 400. However, computer system 500 may perform additional and/or alternative steps. In various embodiments, computer system 500 includes a controller 510 that is digitally implemented and may be programmed using conventional computer components. The controller 510 may be used in conjunction with certain examples (e.g., including devices such as that shown in fig. 1) to implement the processes of such examples. The controller 510 includes a processor 512 that can execute code stored on a tangible computer readable medium in memory 518 (or on a server or other location such as a portable medium in the cloud and other media) to cause the controller 510 to receive and process data and perform actions and/or control components of a device such as that shown in fig. 1. The controller 510 can be any device capable of processing data and executing code, which is a set of instructions that perform actions such as controlling an industrial device. As a non-limiting example, the controller 510 may take the form of: digitally-implemented and/or programmable PID controllers, programmable logic controllers, microprocessors, servers, desktop or laptop personal computers, handheld computing devices, and mobile devices.

Examples of processor 512 include any desired processing circuitry, application Specific Integrated Circuits (ASICs), programmable logic, state machines, or other suitable circuitry. Processor 512 may include one processor or any number of processors. The processor 512 may access code stored in the memory 518 via the bus 514. The memory 518 may be any non-transitory computer readable medium configured to tangibly embody code and may include electronic, magnetic, or optical devices. Examples of memory 518 include Random Access Memory (RAM), read Only Memory (ROM), flash memory, floppy disk, optical disk, digital video device, magnetic disk, ASIC, configured processor, or other storage device.

The instructions may be stored as executable code in the memory 518 or in the processor 512. The instructions may comprise processor-specific instructions generated by a compiler and/or interpreter from code written in any suitable computer programming language. The instructions may take the form of an application that includes a series of set points, parameters for detecting light, and programming steps that, when executed by the processor 512, allow the controller 510 to determine whether the solidified metal 114 has been separated from the mold 120, such as by using the camera 140 to capture light emitted by the light source 150 to detect the light 152 between the mold 120 and the solidified metal 114. Additionally or alternatively, the instructions may include instructions for a machine vision application.

Controller 510 shown in fig. 5 includes an input/output (I/O) interface 516 through which controller 510 may communicate with devices and systems external to controller 510, including components such as flow control device 132, camera 140, light source 150, alarm 170, and/or sensor 180. Input/output (I/O) interface 516 may also receive input data from other external sources, if desired. Such sources may include a control panel, other human/machine interface, computer, server, or other device that may, for example, send instructions and parameters to controller 510 to control its performance and operation; programming of applications that allow the controller 510 to execute instructions in those applications to determine whether the solidified metal 114 has been separated from the mold 120, such as processes incorporating certain examples of the invention; and other data sources necessary or useful for the controller 510 in performing its functions to detect light 152 between the mold 120 and the solidified metal 114 and/or to determine whether the solidified metal 114 has been separated from the mold 120 (such as in the inspection system 100 of fig. 1). Such data may be communicated to input/output (I/O) interface 516 via a network, hardwired, wirelessly, via a bus, or according to other needs.

All patents, publications, and abstracts described above are hereby incorporated by reference in their entirety. The foregoing description of the embodiments, including the illustrative aspects of the embodiments, is given for the purpose of illustration and description only, and is not intended to be exhaustive or limited to the precise forms disclosed. Many modifications, adaptations, and uses of the present invention will be apparent to those skilled in the art.

Illustrative aspects

All patents, publications, and abstracts described above are hereby incorporated by reference in their entirety. The foregoing description of the embodiments, including illustrated aspects of the embodiments, is given for the purpose of illustration and description only, and is not intended to be exhaustive or limited to the precise forms disclosed. Many modifications, adaptations, and uses of the present invention will be apparent to those skilled in the art.

Aspect 1 is a system for detecting metal shrinkage in a mold, comprising: a mold for receiving and containing a metal, the mold comprising a first side, a second side opposite the first side, and a plurality of walls spanning between the first side and the second side; a camera facing the first side of the mold and having a field of view including at least a portion of the first side of the mold; a light source facing the second side of the mold for emitting light directed toward the second side of the mold, the emitted light being visible through the first side of the mold to the camera when the metal is separated from at least one of the plurality of walls; wherein the system is configured to: detecting visible light between the at least one of the plurality of walls and the metal based at least in part on data from the camera; and determining whether separation of the metal from the at least one of the plurality of walls has occurred based at least in part on the light detected to be visible between the at least one of the plurality of walls and the metal.

Aspect 2 is the system of aspect 1 (or any other preceding or subsequent aspect alone or in combination), wherein the first side of the mold is an open top for receiving the metal and the second side of the mold is an open bottom for allowing the metal to exit the mold, or wherein the first side of the mold is an open bottom for allowing metal to exit the mold and the second side of the mold is an open top for receiving the metal.

Aspect 3 is the system of aspect 1 (or any other preceding or subsequent aspect alone or in combination), wherein the mold is a first mold and the field of view of the camera includes the first mold and a second mold, such that the system is capable of detecting separation of the metal from at least one of the plurality of walls in either or both of the first mold and the second mold, and wherein the system is further configured to send a response based at least in part on determining whether separation of the metal and at least one of the plurality of walls has occurred.

Aspect 4 is the system of any one of aspects 1-3 (or any other preceding or subsequent aspect, alone or in combination), wherein the light source is a plurality of light emitting diodes capable of emitting light having a wavelength of 380nm to 740 nm.

Aspect 5 is the system of aspect 1 (or any other preceding or subsequent aspect alone or in combination), further comprising a container positioned above the mold, the container having a bottom and defining a channel for containing the metal, the bottom of the container defining one or more apertures for flow of the metal from the container to the mold, wherein the system is further configured to regulate the flow of the metal from the container to the mold based at least in part on determining whether separation of the metal and at least one of the plurality of walls has occurred.

Aspect 6 is the system of aspect 5 (or any other preceding or subsequent aspect alone or in combination), wherein the camera is a first camera, and the system further comprises a second camera having a field of view different from the field of view of the first camera, and wherein detecting whether light between at least one of the plurality of walls and the metal is visible is based on data from one or both of the first camera or the second camera.

Aspect 7 is the system of aspect 6 (or any other preceding or subsequent aspect, alone or in combination), wherein the mold is a first mold, and the system further comprises a second mold comprising a first side, a second side opposite the first side, and a plurality of sidewalls spanning between the first side and the second side, wherein the second camera has a field of view comprising the first side of the second mold.

Aspect 8 is the system of aspect 7 (or any other preceding or subsequent aspect alone or in combination), wherein the system is further configured to detect whether light is visible between the metal and at least one of the plurality of sidewalls of the first mold based at least in part on data from the first camera, and to detect whether light is visible between the metal and at least one of the plurality of sidewalls of the second mold based at least in part on data from the second camera.

Aspect 9 is the system of aspect 1 (or any other preceding or subsequent aspect alone or in combination), wherein the system further comprises a launder positioned above the mold and configured for depositing the metal into the mold, the launder defining a channel for receiving the metal and comprising a flow control device configured to control a flow rate of the metal into the mold.

Aspect 10 is the system of aspect 9 (or any other preceding or subsequent aspect, alone or in combination), wherein the system is further configured to control the flow rate of the metal into the mold based at least on determining whether separation of the metal and at least one of the plurality of walls has occurred.

Aspect 11 is the system of aspect 10 (or any other preceding or subsequent aspect, alone or in combination), wherein at least a portion of the flow control device is positionable adjacent an aperture defined by a bottom of the launder, and controlling the flow rate of the metal into the mold includes at least changing a position of the flow control device relative to the aperture.

Aspect 12 is the system of aspect 5 (or any other preceding or subsequent aspect, alone or in combination), wherein regulating the flow of the metal from the channel to the mold further comprises: determining a size of the separation between the metal and at least one of the plurality of walls; comparing the size of the separation to a threshold; and increasing the flow of the metal if the size of the separation is less than the threshold, or stopping or decreasing the flow of the metal if the size of the separation is greater than the threshold.

Aspect 13 is the system of aspect 12 (or any other preceding or subsequent aspect, alone or in combination), further comprising a flow control device positioned at least partially adjacent to an aperture of the one or more apertures, wherein increasing the flow of the metal or stopping or reducing the flow of the metal comprises adjusting a position of a flow control device to change a size of the aperture.

Aspect 14 is the system of aspect 13 (or any other preceding or subsequent aspect, alone or in combination), wherein increasing the flow of the metal comprises adjusting the flow control device to increase the size of the pores, or stopping or decreasing the flow comprises adjusting the flow control device to decrease the size of the pores.

Aspect 15 is the system of any one of aspects 9-14 (or any other preceding or subsequent aspect, alone or in combination), wherein the flow control device comprises at least one of a pin, a valve, a stopper, or a funnel.

Aspect 16 is a method for detecting a metal separated from a mold, the method comprising: receiving the metal into the mold, the mold comprising a first face, a second face opposite the first face, and a plurality of sidewalls spanning between the first face and the second face, wherein at least one of the plurality of sidewalls contacts the metal; detecting whether light is present between at least one of the plurality of sidewalls of the mold and the metal based at least on data received from a camera having a field of view of at least a portion of the first face, a light source emitting the light and positioned adjacent to and directing the light toward the second face; and determining whether the metal has been pulled away from at least one of the plurality of sidewalls of the mold based at least on detecting whether the light is present.

Aspect 17 is the method of aspect 16 (or any other preceding or subsequent aspect, alone or in combination), further comprising sending a response based at least on determining that the metal has pulled away from at least one of the plurality of sidewalls of the mold.

Aspect 18 is the method of aspect 17 (or any other preceding or subsequent aspect, alone or in combination), wherein the responding comprises at least one of sending a warning message or activating an alarm.

Aspect 19 is the method of aspect 16 (or any other preceding or subsequent aspect, alone or in combination), wherein causing the metal to be received into the mold comprises operating a flow control device configured for depositing the metal into the mold, the flow control device operable to vary a flow rate of the metal into the mold.

Aspect 20 is the method of aspect 19 (or any other preceding or subsequent aspect, alone or in combination), further comprising operating the flow control device to adjust the flow rate of the metal into the mold based at least on a determination that the metal has pulled away from at least one of the plurality of sidewalls of the mold.

Aspect 21 is the method of aspect 20 (or any other preceding or subsequent aspect, alone or in combination), wherein adjusting the flow rate of the metal into the mold comprises: determining a size of separation between at least one of the plurality of sidewalls and the metal; comparing the size of the separation to a threshold; and increasing the flow rate of the metal if the magnitude of the separation is less than the threshold, or stopping or decreasing the flow rate of the metal if the magnitude of the separation is greater than the threshold.

Aspect 22 is the method of aspect 16 (or any other preceding or subsequent aspect, alone or in combination), further comprising identifying a location where the metal has pulled away from at least one of the plurality of sidewalls of the mold.

Aspect 23 is the method of aspect 16 (or any other preceding or subsequent aspect, alone or in combination), further comprising: identifying a color of ambient light in an environment external to the mold based on data from the camera or data from a light sensor disposed in the environment external to the mold; and controlling the light source to generate light having one or more colors different from the identified color.

Aspect 24 is the method of aspect 16 (or any other preceding or subsequent aspect, alone or in combination), wherein detecting light between at least one of the plurality of sidewalls of the mold and the metal further comprises receiving data from a second camera having a field of view of at least a portion of the first face of the mold.

Aspect 25 is the method of aspect 16 (or any other preceding or subsequent aspect, alone or in combination), wherein detecting light between at least one of the plurality of sidewalls of the mold further comprises moving the camera to change the field of view.

Aspect 26 is the method of aspect 25 (or any other preceding or subsequent aspect, alone or in combination), wherein moving the camera comprises changing the field of view to include at least: one or more portions of the first face or the second face of one or more of a plurality of molds.

Aspect 27 is the method of aspect 16 (or any other preceding or subsequent aspect alone or in combination), wherein determining that the metal has pulled away from at least one of the plurality of sidewalls of the mold is further based on the received information about the mold or the metal.

Claims

1. A system for detecting metal shrinkage in a mold, comprising:

a mold for receiving and containing a metal, the mold comprising a first side, a second side opposite the first side, and a plurality of walls spanning between the first side and the second side;

a camera facing the first side of the mold and having a field of view including at least a portion of the first side of the mold;

a light source facing the second side of the mold for emitting light directed toward the second side of the mold, the emitted light being visible through the first side of the mold to the camera when the metal is separated from at least one of the plurality of walls;

wherein the system is configured to:

detecting visible light between the at least one of the plurality of walls and the metal based at least in part on data from the camera; and

determining whether separation of the metal from the at least one of the plurality of walls has occurred based at least in part on the light detected to be visible between the at least one of the plurality of walls and the metal.

2. The system of claim 1, wherein the first side of the mold is an open top for receiving the metal and the second side of the mold is an open bottom allowing the metal to exit the mold, or wherein the first side of the mold is an open bottom allowing the metal to exit the mold and the second side of the mold is an open top for receiving the metal.

3. The system of claim 1, wherein the mold is a first mold and the field of view of the camera includes the first mold and a second mold, such that the system is capable of detecting separation of the metal from at least one of the plurality of walls in either or both of the first mold and the second mold, and wherein the system is further configured to send a response based at least in part on determining whether separation of the metal and at least one of the plurality of walls has occurred.

4. The system of any one of claims 1 to 3, wherein the light source is a plurality of light emitting diodes capable of emitting light having a wavelength of 380nm to 740 nm.

5. The system of claim 1, further comprising a container positioned above the mold, the container having a bottom and defining a channel for containing the metal, the bottom of the container defining one or more holes for flow of the metal from the container to the mold, wherein the system is further configured to regulate the flow of the metal from the container to the mold based at least in part on determining whether separation of the metal and at least one of the plurality of walls has occurred.

6. The system of claim 5, wherein the camera is a first camera, and the system further comprises a second camera having a field of view different from the field of view of the first camera, and wherein detecting whether light between at least one of the plurality of walls and the metal is visible is based on data from one or both of the first camera or the second camera.

7. The system of claim 6, wherein the mold is a first mold, and the system further comprises a second mold comprising a first side, a second side opposite the first side, and a plurality of sidewalls spanning between the first side and the second side, wherein the second camera has a field of view comprising the first side of the second mold.

8. The system of claim 7, wherein the system is further configured to detect whether light is visible between at least one of the plurality of sidewalls of the first mold and the metal based at least in part on data from the first camera, and to detect whether light is visible between at least one of the plurality of sidewalls of the second mold and the metal based at least in part on data from the second camera.

9. The system of claim 1, wherein the system further comprises a launder positioned above the mold and configured for depositing the metal into the mold, the launder defining a channel for receiving the metal and comprising a flow control device configured to control a flow rate of the metal into the mold.

10. The system of claim 9, wherein the system is further configured to control the flow rate of the metal into the mold based at least on determining whether separation of the metal and at least one of the plurality of walls has occurred.

11. The system of claim 10, wherein at least a portion of the flow control device is positionable adjacent an aperture defined by a bottom of the launder and controlling the flow rate of the metal into the mold comprises at least changing a position of the flow control device relative to the aperture.

12. The system of claim 5, wherein regulating the flow of the metal from the channel to the die further comprises:

determining a size of the separation between the metal and at least one of the plurality of walls;

comparing the size of the separation to a threshold; and

increasing the flow of the metal if the size of the separation is less than the threshold, or stopping or reducing the flow of the metal if the size of the separation is greater than the threshold.

13. The system of claim 12, further comprising a flow control device positioned at least partially adjacent to an aperture of the one or more apertures, wherein increasing the flow of the metal or stopping or reducing the flow of the metal comprises adjusting a position of a flow control device to change a size of the aperture.

14. The system of claim 13, wherein increasing the flow of the metal comprises adjusting the flow control device to increase the size of the pores, or stopping or decreasing the flow comprises adjusting the flow control device to decrease the size of the pores.

15. The system of any one of claims 9 to 14, wherein the flow control device comprises at least one of a pin, a valve, a stopper, or a funnel.

16. A method for detecting a metal separated from a mold, the method comprising:

receiving the metal into the mold, the mold comprising a first face, a second face opposite the first face, and a plurality of sidewalls spanning between the first face and the second face, wherein at least one of the plurality of sidewalls contacts the metal;

detecting whether light is present between at least one of the plurality of sidewalls of the mold and the metal based at least on data received from a camera having a field of view of at least a portion of the first face, a light source emitting the light and positioned adjacent to and directing the light toward the second face; and

determining whether the metal has been pulled away from at least one of the plurality of sidewalls of the mold based at least on detecting whether the light is present.

17. The method of claim 16, further comprising sending a response based at least on determining that the metal has pulled away from at least one of the plurality of sidewalls of the mold.

18. The method of claim 17, wherein the response comprises at least one of sending a warning message or activating an alarm.

19. The method of claim 16, wherein causing the metal to be received into the mold comprises operating a flow control device configured for depositing the metal into the mold, the flow control device operable to vary a flow rate of the metal into the mold.

20. The method of claim 19, further comprising operating the flow control device to adjust the flow rate of the metal into the mold based at least on determining that the metal has pulled away from at least one of the plurality of sidewalls of the mold.

21. The method of claim 20, wherein adjusting the flow rate of the metal into the mold comprises: determining a size of separation between at least one of the plurality of sidewalls and the metal; comparing the size of the separation to a threshold; and increasing the flow rate of the metal if the magnitude of the separation is less than the threshold value, or stopping or decreasing the flow rate of the metal if the magnitude of the separation is greater than the threshold value.

22. The method of claim 16, further comprising identifying a location where the metal has pulled away from at least one of the plurality of sidewalls of the mold.

23. The method of claim 16, further comprising:

identifying a color of ambient light in an environment external to the mold based on data from the camera or data from a light sensor disposed in the environment external to the mold; and

controlling the light source to generate light having one or more colors different from the identified color.

24. The method of claim 16, wherein detecting light between at least one of the plurality of sidewalls of the mold and the metal further comprises receiving data from a second camera having a field of view of at least a portion of the first face of the mold.

25. The method of claim 16, wherein detecting light between at least one of the plurality of sidewalls of the mold further comprises moving the camera to change the field of view.

26. The method of claim 25, wherein moving the camera comprises changing the field of view to include at least: one or more portions of the first face or the second face of one or more of a plurality of molds.

27. The method of claim 16, wherein determining that the metal has pulled away from at least one of the plurality of sidewalls of the mold is further based on information received about the mold or the metal.