KR20230009951A - Detection of metal separation from casting molds - Google Patents

Abstract

Metal may separate from the casting mold during the casting process. A detection system can monitor the mold and determine if metal has separated from the mold. A detection system may include a camera, a light source, and a computer system. A camera and light source may be placed on either side of the casting mold, and both may be positioned facing the mold. The computer system can detect if any light is visible between the mold and the metal based on the data received from the camera. The computer system can then determine that the metal has been removed from the mold based on the detected light.

Description

Detection of metal separation from casting molds

Cross reference to related applications

This application is filed on July 23, 2020, entitled "DETECTING METAL SEPARATION FROM CASTING MOLD", and U.S. Provisional Application No. 62/705,945, filed July 23, 2020, and entitled "Monitoring Casting Environment" 62/705,947, the contents of both of which are incorporated herein in their entirety for all purposes.

technology field

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

Molten metal may be deposited into a mold to create a metal ingot. Such metal ingots may be formed using, for example, direct chill (DC) casting or electromagnetic casting (EMC). In DC casting, molten metal is typically poured into a shallow, water-cooled mold. The mold may include a bottom block mounted on a telescoping hydraulic table to form a false bottom. The bottom block may be placed at or near the bottom of the mold before molten metal is deposited into the mold. As the molten metal is deposited into the mold, it may fill the mold cavity and the outer and lower sides of the mold may cool. 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 metal undergoing cooling may contract and detach from the mold walls, leaving a gap. As additional molten metal is fed into the mold cavity, the newly added molten metal can flow through the gap between the mold wall and the ingot shell and down the outside of the ingot. If the molten metal comes into contact with and/or traps the cooling liquid, it can cause an explosion. Additionally, if the molten metal solidifies in the gap, the ingot may become stuck in the mold as the bottom block continues to lower, leaving a space between the bottom of the ingot and the bottom block. Eventually, the weight of the ingot can drop it from the mold onto the lowered bottom block, causing molten metal to splash out of the mold and into the casting environment.

To mitigate the risks associated with gaps between the ingot and the mold, the operator or operators can look for these gaps, either directly or via a video monitoring system, by observing the edge of the mold during the casting process. However, the operator or operators may miss or overlook the gap because the gap is small or difficult to see. Also, multiple molds may be in use at the same time, requiring the operator or workers to distribute their attention between the molds or multiple workers to monitor the various molds.

The terms embodiments and like terms are intended to refer broadly to all subject matter of this disclosure and claims that follow. Expressions containing these terms are to be understood as not limiting the subject matter described herein or limiting the meaning or scope of the claims below. The embodiments of the present disclosure addressed herein are defined by the claims below, not by the content of the present invention. Aspects of this disclosure are a high-level overview of various embodiments of the invention and introduce some of the concepts further described in the Detailed Description section below. The present disclosure is not intended to identify key 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. This subject matter should be understood with reference to the entire specification, any or all drawings of this disclosure, and appropriate portions of each claim.

Certain examples herein address systems and methods for detecting metal being separated from a casting mold during the casting process. Various examples utilize one or more molds to contain the molten and/or solidified metal during the casting process. At least one of the molds may have a number of sidewalls that span between the top and bottom of the mold. The top and bottom of the mold are 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 with at least one camera having a field of vision that includes at least a portion of the mold. For example, the field of view of one or more cameras may include the top of the mold. A light source may be positioned adjacent to the mold, eg on the opposite side of the mold as one or more cameras. A light source may be positioned to direct light towards the mold. For example, a light source can be positioned to shine light from the bottom of the mold towards a camera at the top of the mold. A computer system may be used to detect whether light is visible between the sidewall of the mold and the solidifying metal in the mold, based on image data received from the camera. The computer system can determine whether the metal in the mold has separated from the sidewall of the mold, eg based on whether the system has detected that light is visible between the solidified metal in the mold and the sidewall of the mold.

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

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

In various examples, a system for detecting the separation of metal from a casting mold is provided. The system may include a mold, a tapping bucket, a camera, lighting, and a computer system. The mold can contain 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 and second sides. The tapping bucket may be positioned above the mold and may include a channel for receiving the molten metal and one or more openings for conveying the molten metal from the tapping bucket to the mold. The camera may have a field of view that includes the first side of the mold. The light can be positioned adjacent to the second side of the mold and can direct the light towards the second side of the mold. The light may be visible to the camera through the first side of the mold when the solidifying metal separates from at least one of the mold walls. A 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 cause the computer system to detect whether light is visible between the mold sidewall and the solidifying metal based at least in part on data from the camera, and based at least in part on the detected light to detect whether light is visible between the mold sidewall and the solidifying metal. It determines whether segregation has occurred and allows the flow of molten metal from the channel to the mold to be adjusted.

In various examples, a system for detecting the separation of metal from a mold is provided. The system comprises a mold configured to receive and contain a metal, the mold including a first side, a second side opposite the first side, and a plurality of sidewalls running between the first side and the second side; a container positioned above a mold having a bottom and defining a channel for receiving metal, the bottom of the mold defining one or more apertures for the flow of metal from the container to the mold; a camera having a field of view that includes the first side of the mold; and a light positioned adjacent the second side of the mold to direct the light towards the second side of the mold, the light being visible to a camera through the first side of the mold when the metal is separated from at least one of the plurality of sidewalls. Lim - may include. The system detects whether light is visible between at least one of the plurality of sidewalls and the metal based at least in part on data from the camera, and detects that the light is visible between the at least one of the plurality of sidewalls and the metal. determine whether separation of the metal from at least one of the plurality of sidewalls has occurred, based at least in part on whether separation of the metal from the at least one of the plurality of sidewalls has occurred The flow of metal from the vessel to the mold can be controlled.

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

This specification refers to the following accompanying drawings, wherein the use of the same reference numbers in different drawings is intended to illustrate the same or similar elements.
1 is a cross-sectional side view of a system for detecting the separation of solidified metal from a mold, in accordance with various embodiments.
2 is a front view of the system of FIG. 1 with multiple molds included, in accordance with various embodiments.
3 is a top view of the mold of FIG. 1 after molten metal is added to the mold, begins to solidify, and is pulled away from the mold sidewalls, in accordance with various embodiments.
4 is a flow diagram illustrating a process for detecting whether solidified metal has separated from a mold, such as by use of the systems of FIGS. 1-3, in accordance with various embodiments.
5 illustrates the exemplary computer system of FIGS. 1 and 2, in accordance with various embodiments.

As used herein, the terms "invention", "invention", "this invention", and "present invention" are intended to refer broadly to all subject matter of this patent application and the following claims. Expressions containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Although the subject matter of the embodiments of the present invention is specifically described herein to satisfy statutory requirements, this 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 with other existing or future technologies. This description is not to be construed as implying any specific order or arrangement between the various steps or elements except where the order of individual steps or arrangement of elements is expressly recited. As used herein, the meanings of “a”, “an”, and “the” include singular and plural references unless the context clearly dictates otherwise.

Although certain aspects of the present disclosure may be suitable for use with any type of material, such as metal, certain aspects of the present disclosure may be particularly suitable for use with aluminum.

All ranges disclosed herein are to be understood to include any and all subranges subsumed therein. For example, a stated range of “1 to 10” includes any and all subranges between (and including) the minimum value of 1 and the maximum value of 10; That is, all sub-ranges beginning with a minimum value greater than or equal to 1, eg, 1 to 6.1, and ending with a maximum value less than or equal to 10, eg, 5.5 to 10, shall be considered inclusive.

The following examples will serve to further illustrate the invention, but at the same time do not limit it. On the contrary, after reading the description herein, it should be clearly understood that reference may be made to various embodiments, modifications, and equivalents thereof that may be suggested to those skilled in the art without departing from the spirit of the invention.

1 and 2 show a detection system 100 for detecting that solidified metal 114 has separated from at least one sidewall of mold 120 and related components, according to certain embodiments. Detection system 100 may include any number of components, but in various embodiments, detection system 100 includes ingot 110, mold 120, camera 140, light source 150, and computer system 160 . 1 and 2 , while detection system 100 is shown as further including a tap 130, detection system 100 may include additional or alternative components.

The ingot 110 may include a molten metal 112 and a solidified metal 114 . In various examples, solidified metal 114 is molten metal 112 that has cooled as it meets the walls of mold 120 . In an illustrative example, molten metal 112 is deposited into mold 120 and begins to solidify to form solidified metal 114 . The bottom block 122 of the mold 120 may be continuously lowered while 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 may continue to elongate ingot 110 .

Ingot 110 may be formed from any metal or combination of metals that can be 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 templates 120 (hereinafter individually or collectively referred to as “templates”) may be provided as part of the detection system 100 . The mold 120 may receive molten metal 112 into one or more mold openings. The molten metal 112 can be contained by the mold 120 and formed into a predetermined shape when the molten metal 112 is cooled to become a solidified metal 114 . The solidified metal 114 (eg, once cooled) may exit the mold 120 through one or more mold outlets. In various embodiments, mold 120 may be rectangular with four side walls, an open top to receive molten metal 112 , and an open bottom through which solidified metal 114 may escape. The mold 120 may additionally or alternatively have or cooperate with a bottom block 122 for forming the ingot 110, as may be typical for molds 120 used in direct cold casting. can Bottom block 122 may be movable or stationary. In some embodiments, bottom block 122 may be a starting head mounted on a telescoping hydraulic table. In alternative embodiments, mold 120 may be of any type and shape suitable for casting molten metal 112 .

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

Molten metal 112 may be deposited by one or more tapping buckets 130 positioned adjacent to mold 120 . Tapping bucket 130 may contain one or more openings for dispensing molten metal 112 into mold 120 . In various embodiments, the tap 130 may be positioned above the mold 120 and deposit molten metal 112 into the mold 120 from one or more openings. The tap 130 may be any size and shape suitable for receiving and dispensing the molten metal 112 . As shown, the tap 130 has a rectangular shape with a u-shaped channel for receiving the molten metal 112 .

The tap tub 130 may further include a flow control device 132 . The flow control device 132 may control the flow rate of the molten metal 112 from the tap 130 to the mold 120 . In an illustrative example, the flow control device 132 may include a pin 134 . A pin 134 may be positioned in an opening 136 in the tap tub 130 . Aperture 136 and/or pin 134 may be tapered such that moving the pin downward relative to the opening makes the annular portion between the pin and the opening smaller. The pin 134 can be raised and/or lowered to adjust the flow of molten metal 112 out of the tap 130 . For example, the pin 134 enlarges the annulus between the pin and the opening 136 to increase the flow of molten metal 112 out of the tap 130 (eg, as shown in solid lines). can be raised for Further, the pin 134 is lowered to reduce the annulus between the pin and the opening 136, thereby reducing the flow of the molten metal 112 out of the tap 130 (e.g., as shown by the dotted line). may be reduced and/or stopped.

Pin 134 may be raised and/or lowered automatically by computer system 160 . For example, pins 134 may be automatically raised and/or lowered to maintain the level of molten metal 112 in mold 120 within a set point range. Pin 134 may additionally or alternatively be automatically raised and/or lowered in response to detecting that the size of ingot 116 is within a specified range. However, 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 pin 134 may be raised and lowered at timed intervals to regulate the flow of the molten metal 112 into the mold 120 (eg, the pin may be pulsed). can). Pulsating the pins 134 can cause the molten metal 112 flowing into the mold 120 to disturb the surface tension of the molten metal in the mold 120 . Disturbing the surface tension of the molten metal 112 in the mold 120 may allow the molten metal to more readily flow along the surface of the molten metal in the mold, eg, into the gap 116 . In further embodiments, the flow control device 132 may additionally or alternatively include a valve, stop, funnel, or other suitable structure.

Detection system 100 may further include one or more cameras 140 capable of capturing still or moving images. Camera 140 may be positioned facing mold 120 or may otherwise have a field of view 142 that includes at least a portion of mold 120 . In various embodiments, camera 140 is positioned over mold 120 with a field of view 142 that includes at least a portion of the top of mold 120 . Camera 140 may additionally or alternatively be positioned below mold 120 with a field of view that includes at least a portion of the bottom of mold 120 . In various embodiments, camera 140 is movable and/or has a changing field of view 142 .

The detection system 100 may include multiple cameras 140 working together. 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 mold 120 and may have overlapping fields of view 142 above 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 can be combined to form an image of the entire side of the mold 120 or to synthesize different regions of interest.

Light source 150 may be positioned on the opposite side of mold 120 as camera 140 . As will be discussed further below when discussing FIG. 3 , the light source 150 can be positioned to emit light directly toward the mold 120 such that a gap 116 (gap 116 as shown) is formed. If silver is exaggerated in size for ease of viewing) between at least one sidewall of the mold 120 and the solidifying metal 114, the emitted light will shine through the gap 116. In a non-limiting example, a camera 140 is positioned above the mold 120 and a light source 150 is positioned below the mold 120 to emit upwardly directed light. Alternatively, a light source 150 may be positioned above the mold 120 to emit light directed downward, and a camera 140 may be positioned below the mold 120 . In a further example, the light and camera can be positioned on the same side of the mold. If present, emitted light visible through gap 116 may be captured, recorded, and/or detected by camera 140 . The emitted light travels indirectly and may be or include light that is scattered, reflected, and/or refracted as it travels from light source 150 through gap 116 to camera 140 . For example, light may be reflected from solidifying metal 114 and/or mold 120 as it travels through gap 116 . However, the light may be or include light that travels directly from light source 150 through gap 116 to camera 140 with little or no reflection or refraction.

Light source 150 may emit light in a single color or may vary between multiple colors. The color may be in the visible or infrared spectrum. In a non-limiting example, light source 150 includes LEDs that can change color. Light source 150 may include an incandescent lamp, a compact fluorescent lamp, a halogen lamp, a metal halide lamp, a light emitting diode (LED), a fluorescent tube, a neon lamp, a high intensity discharge lamp, or other light emitting devices individually or in combination. Additionally, light source 150 may correspond to a component capable of directly emitting light and generating light and/or may additionally or alternatively indirectly emit light and reflect or direct light toward a target focal region. It may include one or more reflective surfaces or other elements on the surface. Further non-limiting examples include mirrors or fiber optic cables for directing light.

Detection system 100 may include computer system 160 . Computer system 160 may include hardware and software for executing computer-executable instructions. For example, computer system 160 may include memory, processors, and an operating system to execute computer-executable instructions (FIG. 5). Computer system 160 may have hardware or software capable of communicating with other devices via a wired connection or a wireless connection (eg, Bluetooth). Computer system 160 may communicate with flow control device 132, camera 140, light source 150, alarm 170 (FIG. 2), or sensor 180 (FIG. 2).

In embodiments, computer system 160 is in a single physical location. For example, computer system 160 is located in the same manufacturing facility as mold 120 and communicates with cameras 140 and/or light source 150 via a local communication network (eg, Wi-Fi or Bluetooth). It can be hardware and software that communicate. Additionally or alternatively, multiple computer systems 160 may communicate with camera 140 and/or light source 150 and/or be located at multiple physical locations. For example, computer system 160 may be a cloud computing system that includes any number of Internet-connected computing components.

The computer system 160 receives data from the camera 140, analyzes the received data to detect light between the mold 120 and the solidifying metal 114, and when the metal 114 moves to the mold ( 120) may include hardware and software that may enable execution of the step of determining whether the Some or all of these steps may be performed by a single computer system 160 or multiple computer systems.

Detection system 100 as shown in FIG. 2 includes additional elements of alarm 170 and sensor 180 . However, the detection system 100 of FIG. 2 may include additional or alternative elements.

The computer system 160 indicates that the solidifying metal 114 has been separated from the mold 120 (e.g., a gap such as gap 116 exists between the mold 120 and the solidifying metal 114, so that the light source 150 After it is determined that the light from ) is detected by the camera 140, the user can be alerted. Computer system 160 may also communicate with alarm 170 . For example, computer system 160 may intervene between one or more sidewalls of mold 120 and solidifying metal 114 (such as when camera 140 captures, records, and/or detects light through gap 116 ). In response to a determination (eg, made by computer system 160) that a gap 116 exists in the alarm 170 may be activated. Alarm 170 may correspond to or include a bell, light, siren, display, speaker, or any other object that may attract a user's attention and/or convey information to the user.

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

In various embodiments, light source 150 may use a different color of light than other colors present in the environment of detection system 100 . This function may be enabled by sensor 180 . Sensor 180 may detect light in the surrounding manufacturing environment and communicate this data to computer system 160 . In a non-limiting example, the surrounding environment contains red light. Sensor 180 detects the red light and sends corresponding data to computer system 160 . Based on that data, computer system 160 sends signals to light source 150 to generate a green light color and/or a light color other than red. In various embodiments, the light source 150 may affect the color that will appear in the field of view of the camera 140 and otherwise detect the presence of a gap 116 between the solidifying metal 114 and the side of the mold 120. different colors from other lights and/or other objects in the relevant surrounding environment, such as the environment around the mold 120, which may negatively affect the ability of the camera 140 to collect distinguishable light for determining It can be tuned during setup by the technician to produce the light color. Additionally or alternatively, in some embodiments, ambient light and/or colors or types of light that may be present in the ambient manufacturing environment are detected by sensor 180 or other suitable input, for example, an aperture ( 116) may be filtered by the computer system 160 to enable detection of the associated emitted light to determine the presence.

As shown in FIG. 2 , detection system 100 may include multiple molds 120A, 120B, and 120C. A number of molds 120A, 120B, 120C may be positioned to receive molten metal 112 from the tap 130 . Alternatively, multiple molds 120A, 120B, 120C may receive molten metal 112 from multiple tap tubs 130 . Multiple molds 120A, 120B, 120C may all contain the same type, alloy, and/or combination of molten metal 112, but each mold 120A, 120B, 120C may contain a different type of molten metal; alloys, and/or combinations may be accommodated.

In various embodiments, one or more cameras 140 and/or one or more light sources 150 are positioned around multiple molds 120A, 120B, 120C. For example, two cameras 140 may be positioned with overlapping fields of view 142 that include at least a portion of first mold 120A. An 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. Additionally, a movable camera 140 may be positioned with a field of view 142 that includes at least a portion of the third mold 120C. One or more light sources 150 may be positioned on opposite sides of multiple molds 120A, 120B, 120C as one or more cameras 140 .

Referring to FIG. 3 , an example field of view 142 of the camera 140 of FIGS. 1 and 2 is shown. Field of view 142 may include mold 120 , molten metal 112 , and solidified metal 114 . Field of view 142 also includes gap 116 between at least one sidewall of mold 120, if present, and light 152 (eg, from light source 150) shining through gap 116. can include As shown, field of view 142 includes one side (eg, top) of mold 120 and the entire periphery of mold 120 . However, field of view 142 may be limited to a sub-portion of the periphery of mold 120, multiple molds, such as portions of molds 120A, 120B, and 120C, multiple sides of mold 120, or It may include multiple sides of multiple molds 120A, 120B, and 120C.

As an example, field of view 142 is shown as being divided into four quadrants (eg, I, II, III, IV). However, 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 combination of quadrants. In some embodiments, a single camera 140 may have multiple fields of view 142 that the camera 140 may switch to (eg, each quadrant is a different field of view 142 ). For example, movable camera 140 can switch between fields of view 142 as camera 140 pans around the top of mold 120 .

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

4 is a flowchart illustrating an example of a process 400 for using the detection system 100 to identify a gap 116 between the sidewall of a mold 120 and the solidifying metal 114 in accordance with some embodiments. . Some or all of process 400 (or any other processes, or variations, and/or combinations thereof described herein) may be performed under the control of one or more computer systems composed of executable instructions; , hardware, or combinations thereof, as code (eg, executable instructions, one or more computer programs, or one or more applications) that collectively executes on one or more processors. The code may be stored on a computer readable storage medium, for example in the form of a computer program comprising a plurality of instructions executable by one or more processors. A computer readable storage medium may be non-transitory. Also, unless otherwise indicated, some operations shown as processes need not be performed in the order shown and/or may be omitted from embodiments.

Process 400 may include depositing at 402 a metal, such as molten metal 112 , to one or more molds, such as mold 120 . Molten metal 112 may be deposited into mold 120 by tapping bucket 130 as described herein. The tapping tub 130 may deposit molten metal 112 into the mold 120 through one or more openings in the tapping tub 130 . The amount or flow rate of molten metal 112 entering the mold 120 can be adjusted by controlling the flow control device 132 . Molten metal 112 may enter mold 120 through one or more openings in mold 120 . Molten metal 112 received by mold 120 may contact one or all of the sidewalls of mold 120 . The temperature of the molten metal 112 may decrease after entering the mold 120 , and the molten metal 112 may cool to solidify metal 114 . The solidified metal 114 may shrink away from the sidewalls of the mold 120 causing one or more gaps 116 to form between the solidified metal 114 and the sidewalls of the mold 120 .

Process 400 may include emitting light, such as light 152, from a light source, such as light source 150 described above at 403. Light source 150 may be positioned on the opposite side of mold 120 and oriented to emit light 152 towards the lens of a camera, such as camera 140 . Solidifying metal 114 in mold 120 may block emitted light 152 if solidifying metal 114 is in contact with all sides of mold 120 . However, if a gap such as gap 116 exists between solidifying metal 114 and mold 120, the emitted light passes through gap 116 and can be seen by camera 140. Light source 150 can emit light 152 comprising multiple colors. For example, the light source 150 may emit light of a specific color different from the color of light visible in the surrounding environment. In some embodiments, sensor 180 is used to detect a light source in the surrounding environment. In some cases, sensor 180 sends detected light data to a computer, such as computer system 160, which instructs light source 150 to illuminate light 152 of a color other than the color of the detected light. send out

Process 400 may include detecting light between the sidewall of mold 120 and solidifying metal 114 at 404 . The detected light may be light 152 emitted by light source 150 . In some embodiments, detected light 152 is ambient light in an ambient environment. Light 152 can be detected after passing through gap 116 between mold 120 and solidifying metal 114 . Camera 140 can see light through gap 116 . Camera 140 may then send data to computer system 160 indicating that light is seen between mold 120 and solidifying metal 114 . Computer system 160 may process the data and determine that light was detected between the sidewall of mold 120 and solidifying metal 114 .

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

Computer system 160 may use additional or alternative data received from camera 140 to determine that solidified metal 114 has been removed from mold 120 . In some embodiments, computer system 160 may retrieve mold 120 and/or solidification from a data source (eg, database) to help determine whether solidifying metal 114 has separated from mold 120 . Information about metal 114 may be received. In the illustrative example, first mold 120A and second mold 120B are monitored by camera 140 . Computer system 160 receives information that solidified metal 114 in first mold 120A is more likely to separate from first mold 120A than solidified metal 114 in second mold 120B ( For example, the first mold 120A may be located in a region closer to the cooling source than the second mold 120B, so that the solidified metal 114 in the first mold cools more rapidly and the first mold 120A are more likely to shrink away from the walls). In response to the received information, computer system 160 instructs camera 140 to keep more of first mold 120A within field of view 142 of camera 140 .

Process 400 may include responding to a determination of computer system 160 that solidifying metal 114 has separated from the sidewalls of mold 120 at 408 . The response may include alerting the user. An alert may be sent to the user by the computer system 160 to inform the user that the solidifying metal 114 has separated from the mold 120 . For example, the alert may be activating an alarm such as alarm 170 described above and alerting the user that separation has occurred. Additionally or alternatively, an alert may be a message, visual indication, or audible indication that draws the user's attention and/or alerts the user to disconnect.

Additionally or alternatively, computer system 160 may respond to the separation of mold 120 from solidified metal 114 by changing the flow rate of molten metal 112 into mold 120 . As the molten metal 112 is deposited into the mold 120, it may flow into a gap 116 caused by contraction of the solidified metal 114 away from the mold. Gaps 116 may be small, for example, so that molten metal 112 can be added to mold 120 to fill the gaps. In contrast, gap 116 can be large, for example, so that molten metal 112 can be added to mold 120 and flow through gap 116 and exit the bottom of mold 120 . In some embodiments, molten metal 112 flowing through gap 116 may come into contact with water and/or cooling liquid, which may cause an explosion. Thus, computer system 160 may determine the size of gap 116 and use that information to determine whether to change the flow rate in response to gap 116 .

In various embodiments, gap 116 may be filled by adjusting the flow of molten metal 112 into mold 120 . For example, the flow rate of molten metal 112 into mold 120 may be adjusted by flow control device 132 . The flow of molten metal 112 into mold 120 is responsive to computer system 160 detecting gap 116 (and/or detecting that gap 116 is small enough to be filled). This can be increased, for example, by raising the pin and increasing the flow rate of molten metal through the opening of the tap 130. Additionally or alternatively, the height of the pins may be pulsated to change the flow rate of molten metal 112 into mold 120 . The increased and/or changing flow rate of molten metal 112 may cause molten metal 112 to flow into gap 116 . 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 stop or prevent additional molten metal 112 from flowing through the gap. If the gap 116 is large, the computer system 160 can issue instructions to the flow control device 132 to reduce or stop the flow of the molten metal 112 into the mold 120 . Computer system 160 may also prompt or cause a change in flow rate by issuing instructions to a user.

In some embodiments, process 400 includes steps 410 - 414 for responding to the separation of solidified metal 114 from mold 120 . The process 400 may include determining the size of the gap 116 between the solidifying metal 114 and the mold 120 at 410 . In various examples, computer system 160 sends data to camera 140 that includes or contains the amount of light 152 captured by camera 140 in gap 116 between solidifying metal 114 and mold 120 . ) is received from 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 comparing the size of the gap 116 between the solidifying metal 114 and the mold 120 to a threshold value at 412 . The threshold may be received by computer system 160 and may be based at least on the type of ingot 110 being formed, the type of mold 120 , and/or other characteristics of detection system 100 . Process 400 may include increasing or decreasing the flow of molten metal 112 into mold 120 based on the comparison of gap 116 to a threshold at 414 . For example, if gap 116 is less than a threshold value, the flow of molten metal 112 into mold 120 may be increased. Additionally or alternatively, if gap 116 is greater than a threshold value, the flow of molten metal 112 into mold 120 may be reduced and/or stopped.

FIG. 5 is an exemplary computer system 500 for use with a system for detecting the separation of solidified metal 114 from mold 120 , as shown in FIG. 1 . In some embodiments, computer system 500 performs one, some, or all of the steps of 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 programmable using conventional computer components. Controller 510 may be used in connection with certain examples (eg, including equipment as shown in FIG. 1 ) to perform the processes of these examples. Controller 510 may read tangible computer data within memory 518 to cause controller 510 to receive and process data and perform operations and/or control components of the equipment as shown in FIG. and a processor 512 capable of executing code stored on an available medium (or elsewhere, such as a portable medium, among other mediums, on a server, or in the cloud). Controller 510 may be any device capable of executing code, which is a set of instructions for processing data and performing operations such as controlling industrial equipment. As non-limiting examples, the controller 510 may include a digitally implemented and/or programmable PID controller, a programmable logic controller, a microprocessor, a server, a desktop or laptop personal computer, a laptop personal computer, a handheld computing device, and a mobile device. may take the form of

Examples of processor 512 include any desired processing circuitry, application specific integrated circuit (ASIC), programmable logic, state machine, or other suitable circuitry. Processor 512 may include one processor or any number of processors. Processor 512 may access code stored in memory 518 via bus 514 . 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, compact disk, digital video device, magnetic disk, ASIC, configured processor, or other storage device.

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

Controller 510 shown in FIG. 5 includes components such as flow control device 132, camera 140, light source 150, alarm 170, and/or sensor 180, so that controller 510 ) an input/output (I/O) interface 516 through which the controller 510 can communicate with external devices and systems. Input/output (I/O) interface 516 can also receive input data from other external sources, if desired. These sources, for example, send instructions and parameters to the controller 510 to control the performance and operation of the controller 510; The controller 510 stores and enables programming of applications that enable the execution of instructions in the applications to determine whether the solidified metal 114 has separated from the mold 120, such as in connection with the processes of certain examples of the present invention. control panels, other human/machine interfaces, computers, servers or other equipment capable of enabling; and, such as in system 100 of FIG. 1 , controller 510 detects light 152 between mold 120 and solidified metal 114 and/or determines whether solidified metal 114 has separated from mold 120 . It may include other data sources necessary or useful in performing its functions of determining . Such data may be communicated to input/output (I/O) interface 516 over a network, hardwire, wirelessly, over a bus, or otherwise as desired.

All cited patent publications, publications and abstracts are incorporated herein in their entirety. The foregoing description of the present embodiments, including exemplary aspects of the embodiments, has been presented for purposes of illustration and description only, and is not intended to be exhaustive or limiting to the exact forms disclosed. Numerous variations, adaptations and uses thereof will be apparent to those skilled in the art.

exemplary aspects

All cited patent publications, publications and abstracts are incorporated herein in their entirety. The foregoing description of the present embodiments, including exemplary aspects of the embodiments, has been presented for purposes of illustration and description only, and is not intended to be exhaustive or limiting to the exact forms disclosed. Numerous variations, adaptations and uses thereof will be apparent to those skilled in the art.

Aspect 1 is a system for detecting shrinkage of metal in a mold, comprising a mold for receiving and containing metal, the mold having a first side, a second side opposite the first side, and between the first side and the second side. including a plurality of walls spanning ―; a camera facing the first side of the mold and having a field of view that includes at least a portion of the first side of the mold; A light source directed towards the second side of the mold to emit light directed towards the second side of the mold, wherein the emitted light is visible to a camera through the first side of the mold when the metal is separated from at least one of the plurality of walls. Lim - includes; The system is configured to: detect visible light between the metal and at least one of the plurality of walls based at least in part on data from the camera; and is configured to determine whether separation of the metal from the at least one of the plurality of walls has occurred based at least in part on light being detected as being visible between the at least one of the plurality of walls and the metal.

Aspect 2 is according to aspect(s) 1 (or any other preceding or succeeding aspects, individually or in combination) wherein the first side of the mold is an open top for receiving a metal and the second side of the mold is a metal system that is an open bottom to allow exit of the mold, or where the first side of the mold is an open bottom to allow metal to exit the mold and the second side of the mold is an open top to receive the metal. to be.

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

Aspect 4 is the aspect of any one of aspect(s) 1 to 3 (or any other preceding or succeeding aspects, individually or in combination) wherein the light source is capable of emitting light in a wavelength of 380 to 740 nm. A system that is a plurality of light emitting diodes.

Embodiment 5 is according to aspect(s) 1 (or any other preceding or succeeding aspects, individually or in combination), further comprising a vessel positioned above a mold having a bottom and defining a channel for containing a metal; The bottom of the vessel defines one or more apertures for the flow of metal from the vessel to the mold, and the system also determines that separation of the metal from at least one of the plurality of walls has occurred, at least in part, from the vessel to the mold. The system is configured to regulate the flow of metal into the system.

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

Aspect 7 is according to aspect(s) 6 (or any other preceding or succeeding aspects, individually or in combination), wherein the mold is the first mold, and the system is configured on the first side, on the second side opposite the first side. The system further includes a second mold comprising a side and a plurality of sidewalls spanning between the first side and the second side, wherein the second camera has a field of view that includes the first side of the second mold. .

Aspect 8 is according to aspect(s) 7 (or any other preceding or succeeding aspects, individually or in combination), further comprising a plurality of sidewalls of the first mold based at least in part on data from the first camera. 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 and whether light is visible between the metal and at least one of the plurality of sidewalls of the second mold; It is a system that will be.

Aspect 9 is according to aspect(s) 1 (or any other preceding or succeeding aspects, individually or in combination), wherein the system further comprises a launder positioned over the mold and configured to deposit metal into the mold; , wherein the tapping bucket defines a channel for receiving the metal and includes a flow control device configured to control the flow rate of the metal into the mold.

Aspect 10 is according to aspect(s) 9 (or any other preceding or succeeding aspects, individually or in combination), also based at least on determining whether separation of metal from at least one of the plurality of walls has occurred. and configured to control the flow rate of metal into the mold by

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

Aspect 12 is according to aspect(s) 5 (or any other preceding or succeeding aspects, individually or in combination) wherein the controlling the flow of metal from the channel to the mold is between at least one of the plurality of walls and the metal. determining the size of the separation; comparing the magnitude of the separation to a threshold; and increasing the flow of metal if the size of the separation is less than the threshold value, or stopping or reducing the flow of metal if the size of the separation is greater than the threshold value.

Aspect 13 further comprises the flow control device of aspect(s) 12 (or any other preceding or succeeding aspects, individually or in combination), positioned at least partially adjacent one of the one or more apertures. wherein increasing the flow of metal or stopping or reducing the flow of metal includes adjusting the position of the induction control device to change the size of the aperture.

Aspect 14 is according to aspect(s) 13 (or any other preceding or succeeding aspects, individually or in combination) wherein increasing the flow of the metal comprises adjusting the flow control device to increase the size of the aperture. The system comprising, or stopping or reducing the flow comprises adjusting the flow control device to reduce the size of the aperture.

Aspect 15 is according to any one of aspects 9 to 14 (or any other preceding or succeeding aspects, individually or in combination), wherein the flow control device comprises at least one of a pin, a valve, a stop, or a funnel. person, it is a system.

Embodiment 16 is a method for detecting separation of metal from a mold, wherein the metal is received into the mold, wherein the mold comprises a first face, a second face opposite the first face, and a first face and a second face. including a plurality of sidewalls extending therebetween, and at least one of the plurality of sidewalls is in contact with a 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 surface, wherein the light source emits light and the second surface positioned adjacently and directing the light towards the second side; and determining whether metal has been detached from at least one of the plurality of sidewalls of the mold based at least on detecting that light is present.

Aspect 17 is the method of aspect(s) 16 (or any other preceding or succeeding aspects, individually or in combination), wherein the response is based at least on determining that metal has been detached from at least one of the plurality of sidewalls of the mold. It is a method, further comprising the step of sending a call.

Aspect 18 is according to aspect(s) 17 (or any other preceding or succeeding aspects, individually or in combination) wherein the response comprises sending at least one alert message or activating an alarm. , the way

Aspect 19 is according to aspect(s) 16 (or any other preceding or succeeding aspects, individually or in combination) wherein causing the metal to be received into the mold operates a flow control device configured to deposit the metal into the mold. and wherein the flow control device is operable to vary the flow rate of the metal into the mold.

Aspect 20 relates to aspect(s) 19 (or any other preceding or succeeding aspects, individually or in combination) wherein the flow control based at least on determining that metal has been disengaged from at least one of the plurality of sidewalls of the mold. The method further includes actuating the device to adjust the flow rate of the metal into the mold.

Aspect 21 is the method of aspect(s) 20 (or any other preceding or succeeding aspects, individually or in combination), wherein adjusting the flow rate of the metal into the mold is a barrier between at least one of the plurality of sidewalls and the metal. determining the size of the separation; comparing the magnitude of the separation to a threshold value; and increasing the flow rate of the metal if the size of the separation is less than the threshold value, or stopping or reducing the flow rate of the metal if the size of the separation is greater than the threshold value.

Aspect 22 is of aspect(s) 16 (or any other preceding or succeeding aspects, individually or in combination), further comprising identifying a location where the metal is disengaged from at least one of the plurality of sidewalls of the mold. way to do it.

Aspect 23 is according to aspect(s) 16 (or any other preceding or succeeding aspects, individually or in combination), based on data from a camera or data from a light sensor disposed in an environment outside the mold, outside the mold. identifying colors of ambient light in the environment of ; and controlling the light source to produce light having a color or colors different from the identified colors.

Aspect 24 is an aspect of aspect(s) 16 (or any other preceding or succeeding aspects, individually or in combination) wherein detecting light between at least one of the plurality of sidewalls of the mold and the metal comprises: and receiving data from a second camera having a field of view of at least a portion of the first surface.

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

Aspect 26 is according to aspect(s) 25 (or any other preceding or succeeding aspects, individually or in combination), wherein moving the camera is a first face or a second face of one or more of the plurality of molds. and altering the field of view to include at least one or more portions of the .

Aspect 27 is of aspect(s) 16 (or any other preceding or succeeding aspects, individually or in combination), wherein determining that metal has been detached from at least one of the plurality of sidewalls of the mold further comprises: based on information received about the metal.

Claims (27)

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 that includes at least a portion of the first side of the mold;
A light source directed towards the second side of the mold to emit light directed towards the second side of the mold, wherein the emitted light is directed toward the first side of the mold when the metal is separated from at least one of the plurality of walls. visible to the camera through the side;
The system:
detect visible light between the metal and at least one of the plurality of walls based at least in part on data from the camera; And
determining whether separation of the metal from at least one of the plurality of walls has occurred based at least in part on the light being detected as being visible between at least one of the plurality of walls and the metal. , system. The method of claim 1 , wherein the first side of the mold is an open top to receive the metal, and the second side of the mold is an open bottom to allow the metal to exit the mold, or wherein one side is an open bottom to allow the metal to exit the mold and a second side of the mold is an open top to receive the metal. The method of claim 1 , wherein the mold is a first mold and the camera's field of view allows the system to separate the metal from at least one of the plurality of walls in either or both of the first mold and the second mold. the first mold and the second mold to enable detection, the system further to send a response based at least in part on determining whether separation of the metal from at least one of the plurality of walls has occurred. system configured to do so. 4. The system according to any one of claims 1 to 3, wherein the light source is a plurality of light emitting diodes capable of emitting light in a wavelength of 380 to 740 nm. 2. The method of claim 1 further comprising a vessel positioned above the mold having a bottom and defining a channel for containing the metal, wherein the bottom of the vessel comprises one or more vessels for the flow of the metal from the vessel to the mold. defines an aperture, and the system is further configured to adjust the flow of the metal from the container to the mold based at least in part on whether separation of the metal from at least one of the plurality of walls has occurred. that is, the system. 6. The method 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 that of the first camera, wherein light passes between at least one of the plurality of walls and the metal. and wherein detecting whether it is visible is based on data from one or both of the first camera or the second camera. 7. The method of claim 6 wherein the mold is a first mold and the system comprises 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 system of claim 1 , further comprising a second mold comprising: and wherein the second camera has a field of view that includes the first side of the second mold. 8. The method of claim 7, wherein the system further determines 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 whether the first mold is visible. 2 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 camera. 2. The system of claim 1 further comprising a launder positioned over the mold and configured to deposit the metal into the mold, the launder defining a channel for receiving the metal and into the mold. a flow control device configured to control the flow rate of the metal in the system. 10. The method 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 from at least one of the plurality of walls has occurred. system. 11. The method of claim 10, wherein at least a portion of the flow control device is positionable adjacent an aperture defined by a bottom of the tapping tub, and controlling the flow rate of the metal into the mold is a method of controlling the flow rate relative to the aperture. The system of claim 1 , comprising at least changing a position of the flow control device. 6. The method of claim 5 wherein adjusting the flow of the metal from the channel to the mold comprises:
determining a size of a separation between at least one of the plurality of walls and the metal;
comparing the magnitude of the separation to a threshold value; and
and increasing the flow of the metal if the magnitude of the separation is less than the threshold value, or stopping or reducing the flow of the metal if the magnitude of the separation is greater than the threshold value. 13. The method of claim 12, further comprising a flow control device positioned at least partially adjacent one of the one or more apertures, wherein increasing the flow of the metal or stopping or reducing the flow of the metal is and adjusting the position of the induction control device to change the size of the aperture. 14. The method of claim 13, wherein increasing the flow of the metal comprises adjusting the flow control device to increase the size of the aperture, or stopping or reducing the flow decreases the size of the aperture. and adjusting the flow control device to 15. The system of any one of claims 9-14, wherein the flow control device comprises at least one of a pin, valve, stop, or funnel. A method for detecting the separation of metal from a mold, comprising:
allowing the metal to be received into the mold, wherein the mold includes a first face, a second face opposite the first face, and a plurality of sidewalls extending between the first face and the second face; , at least one of the plurality of sidewalls is in contact with 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 surface, wherein a light source emits the light; positioned adjacent to the second face and directing the light toward the second face; and
determining whether the metal has been detached from at least one of the plurality of sidewalls of the mold based at least on detecting that the light is present. 17. The method of claim 16, further comprising sending a response based at least on determining that the metal has been pulled from at least one of the plurality of sidewalls of the mold. 18. The method of claim 17, wherein the response includes sending at least one alert message or activating an alarm. 17. The method of claim 16, wherein causing the metal to be received into the mold includes activating a flow control device configured to deposit the metal into the mold, the flow control device configured to deposit the metal into the mold. wherein the method is operable to change the flow rate. 20. The method of claim 19, further comprising activating the flow control device to adjust the flow rate of the metal into the mold based at least on determining that the metal has disengaged from at least one of the plurality of sidewalls of the mold. How to. 21. The method of claim 20, wherein adjusting the flow rate of the metal into the mold comprises: determining a size of a separation between the metal and at least one of the plurality of sidewalls; comparing the magnitude of the separation to a threshold value; and increasing the flow rate of the metal if the magnitude of the separation is less than the threshold, or stopping or reducing the flow rate of the metal if the magnitude of the separation is greater than the threshold. . 17. The method of claim 16, further comprising identifying a location where the metal has disengaged from at least one of the plurality of sidewalls of the mold. According to claim 16,
identifying colors 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 produce light having a color or colors different from the identified colors. 17. The method of claim 16, wherein detecting light between at least one of the plurality of sidewalls of the mold and the metal comprises receiving data from a second camera having a field of view of at least a portion of the first surface of the mold. Further comprising, the method. 17. 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 includes changing the field of view to include at least a portion of one or more of the first or second side of one or more of the plurality of molds. . 17. The method of claim 16, wherein determining that the metal has come off from at least one of the plurality of sidewalls of the mold is also based on information received about the mold or the metal.

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