RU2813254C1 - Control of ingot formation - Google Patents

Abstract

FIELD: continuous casting of metal.

SUBSTANCE: mould control system contains a mould (102) with a hole for receiving molten metal (106) and a lower block lowered during casting, a chute for feeding metal into the mould, a water source for supplying water into the mould, a diverter for draining water from ingot parts, chamber (110) and controller (112). The camera's field of view includes the portion of the ingot from which water has been drained. The controller includes a processor that executes instructions stored on a computer-readable medium in a storage device. The camera receives or detects the optical data of the moulds and sends it to the controller. The controller compares the optical data with the base profile, determines whether the ingot has separated from the lower block, and the height of the separation. Then, based on the specified separation, it generates operating commands to regulate the casting process.

EFFECT: enables control and regulation of the casting process.

20 cl, 7 dwg

Description

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims benefit and priority to US Provisional Patent Application No. 62/705949, filed July 23, 2020, entitled MONITORING INGOT FORMATION, the contents of which are incorporated herein by reference in their entirety for all purposes.

TECHNICAL FIELD

[0002] The present invention relates generally to metal casting and, more particularly, to related methods and systems for monitoring a metal casting process.

BACKGROUND OF THE ART

[0003] Molten metal can be placed in a mold to create a metal ingot. These metal ingots can be produced, for example, using continuous mold casting (DC - direct chill) or electromagnetic casting (EMC). In continuous mold casting, the molten metal is usually poured into a shallow, water-cooled mold. The mold may include a bottom block mounted on a telescopic hydraulic table to form a double bottom. The bottom block may be located at or near the bottom of the mold before the molten metal is placed into the mold. As molten metal is placed into the mold, the molten metal can fill the mold cavity and the outside and bottom of the mold can 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 lower block is lowered, additional molten metal may be introduced into the mold cavity.

[0004] Before, during, and after the casting process, the mold and metal ingot may be monitored by one or more sensors. For example, a metal level sensor can measure the height of molten metal in a mold. Many of these sensors are placed in and around the mold and often come into physical contact with the ingot or mold. To reduce the risk of operator exposure to the casting environment and the presence of sensors in contact with the ingot, it may be desirable to monitor the casting process from outside the casting environment using a system that does not come into contact with the ingot.

SUMMARY OF THE INVENTION

[0005] The term “embodiments” and similar terms are intended to broadly refer to the entire subject matter of the present invention and the following claims. Statements containing these terms are to be understood as not limiting the subject matter described herein or limiting the meaning or scope of the claims set forth below. The embodiments of the present invention described herein are defined by the claims below and not by the present specification. This summary provides a general overview of various aspects of the present invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The subject matter should be understood by reference to relevant portions of the entire specification of the present invention, any or all of the drawings, and each claim.

[0006] Some examples herein discuss systems and methods for monitoring a casting system during the casting process. Various examples employ casting systems that include a launder for feeding molten metal into one or more molds during the casting process. At least one of the molds may have multiple side walls extending between the top and bottom of the mold. The top and bottom of the mold may be open, allowing a trough to deposit molten metal through the open top and allowing solidifying metal to escape through the open bottom. The system may include one or more cameras, wherein at least one camera has a field of view 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 a mold. A computer system may be used to detect one or more events during a casting operation, such as the level of metal in a mold or the distance between a lower block and a portion of a metal ingot. The computer system may determine an appropriate action and/or warning based on one or more detected events.

[0007] Various examples provide a system for monitoring a foundry operation. The system may include a mold defining an opening for receiving molten metal, a lower block lowered to receive molten metal, a trough including a flow control device configured to control the rate of flow of molten metal from the trough into the mold for casting the molten metal into the ingot, and a water source configured to supply water to the mold. Water can leak out of the mold while molten metal is being cast into an ingot. The system may also include a camera having a field of view including at least a lower block portion and a ingot portion, and configured to obtain optical data associated with the ingot portion or the lower block portion, and a controller including a processor configured to the ability to execute commands stored on a non-volatile machine-readable medium in a storage device. The controller may cause the processor to perform processor operations including receiving optical data associated with the ingot portion or the lower block portion; determining, based on the optical data, whether a portion of the ingot has separated from a portion of the lower block; and generating operating commands to cast the molten metal into an ingot if it is determined that separation has occurred.

[0008] Various examples provide a method for inspecting a casting mold. The method may include starting a casting operation using a casting system including a mold, a lower block, and a launder. A foundry operation may include allowing molten metal to flow into a mold, allowing water to flow into the mold, cooling the molten metal to form an ingot, lowering a lower block, and draining water from a portion of the ingot. The inspection method may also include using a camera to obtain first optical data associated with a portion of the ingot; comparison of the first optical data with the base profile; and determining, based on the comparison, whether a portion of the ingot has separated from the lower block.

[0009] In various examples, a mold inspection system is proposed. The system may include a mold defining an opening for receiving molten metal and a bottom block lowered during casting of the molten metal into the ingot, a chute configured to supply molten metal to the mold, a water source configured to supply water to the mold , a diverter configured to remove water from a portion of the ingot, a camera having a field of view including at least that portion of the ingot from which water has been removed and configured to receive optical data associated with the ingot, and a controller including a processor configured to execute instructions stored on a nonvolatile computer-readable medium in a storage device. The controller may cause the processor to perform a processor operation including obtaining first optical data associated with the ingot portion; generating a profile associated with a region of the ingot based on at least the first optical data; comparison of the profile with the base profile; and determining, based on the comparison, whether a portion of the ingot has separated from the lower block.

[0010] Other objects and advantages will be apparent from the following detailed description of non-limiting examples.

BRIEF DESCRIPTION OF GRAPHIC MATERIALS

[0011] Reference is made in the specification to the following accompanying drawings, in which the use of like reference numerals in different drawings is intended to illustrate like or similar components.

[0012] In FIG. 1 is an illustration of a casting environment control system in accordance with various embodiments.

[0013] In FIG. 2 is a cross-sectional view of a portion of the monitoring system shown in FIG. 1, in accordance with various embodiments.

[0014] In FIG. 3 is a top view of part of the control system shown in FIG. 1, in accordance with various embodiments.

[0015] In FIG. 4 illustrates an exemplary computer system for use with the monitoring system shown in FIG. 1, in accordance with various embodiments.

[0016] In FIG. 5A and 5B show a portion of an exemplary casting system for use with the inspection system shown in FIG. 1, according to various embodiments

[0017] In FIG. 6A and 6B show a portion of the exemplary casting system shown in FIG. 5A and 5B, during the casting process, in accordance with various embodiments.

[0018] In FIG. 7 is a block diagram representing an exemplary method of applying a monitoring system, in accordance with various embodiments.

DETAILED DESCRIPTION OF THE INVENTION

[0019] As used herein, the terms “invention,” “this invention,” “this invention,” and “the present invention” are intended to broadly refer to the entire subject matter of this patent application and the claims below. Statements containing these terms are to be understood as not limiting the subject matter described herein or limiting the meaning or scope of the claims set forth below. The subject matter of embodiments of the present invention is described herein with specificity to satisfy legal requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be implemented in other ways, may include other elements or steps, and may be used in combination with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement between various steps or elements, unless the order of individual steps or arrangement of elements is explicitly described. As used herein, the singular forms include singular and plural references unless the context clearly indicates otherwise.

[0020] Although some aspects of the present invention may be suitable for use with any type of material, such as metal, some aspects of the present invention may be particularly suitable for use with aluminum.

[0021] It should be understood that all ranges described herein cover any and all sub-ranges included herein. For example, the stated range "1 to 10" should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges starting with a minimum value of 1 or more, such as 1 to 6.1, and ending with a maximum value of 10 or less, such as 5.5 to 10.

[0022] The following examples will serve to further illustrate the present invention, but at the same time, however, will not constitute any limitation thereof. On the contrary, it should be clearly understood that reference may be made to various embodiments, modifications and equivalents thereof which may come to the mind of those skilled in the art after reading the present description without departing from the spirit of the present invention.

[0023] In FIG. 1 illustrates a monitoring system 100 for monitoring a foundry system, including one or more molds 102 and associated components, in accordance with some embodiments. The control system 100 may include any number of components, however, in various embodiments, the control system 100 includes a chute 104 located above one or more molds 102. The chute 104 may have one or more openings for placing molten metal 106 into the molds 102. Molten metal 106 may be cooled to form a solid or semi-solid ingot 108 during the casting process. One or more cameras 110 may be located in the foundry environment to detect or obtain optical data associated with one or more components. For example, cameras 110 may receive optical data associated with molten metal 106. The optical data may be processed by computer system 112 to monitor one or more casting operations.

[0024] With the monitoring system 100, various components used in the casting process can be monitored remotely. For example, cameras, such as cameras 110, can monitor the casting environment and/or casting components. Remote control allows the user to remain outside or enter the foundry environment for a shorter time than would otherwise be required. In addition, multiple aspects of the foundry environment can be monitored simultaneously, reducing the need for additional monitoring systems. Remote monitoring may also ensure that part or all of the monitoring system 100 is located further away from one or more heat sources in the foundry environment. For example, rather than placing the sensor equipment adjacent to or attached to the mold 102 where it may be subject to extreme heat from the molten metal 106, the cameras 110 may be located away from the mold 102 and/or the molten metal 106 in a cooler environment. Placing control equipment away from heat sources can additionally or alternatively reduce the number of repairs and replacements, saving time and money.

[0025] Molds 102 may be positioned in the casting medium and receive molten metal 106 into the opening of the mold. The mold 102 may include a material that can withstand the temperature of the molten metal 106 as it cools to form an ingot 108. For example, the mold 102 may include graphite. The mold 102 may have any suitable shape or design for receiving and cooling molten metal 106. In various embodiments, the mold 102 may have a rectangular cross-section with four mold walls and an open top to receive molten metal 106 and an open bottom to allow the ingot to exit 108. In some embodiments, the mold 102 may include or cooperate with a lower block 114 to form an ingot 108, which is typically the case in a mold 102 used in continuous mold casting. The lower block 114 may be movable or fixed. In some embodiments, the lower block 114 may be a launch head mounted on a telescopic hydraulic table. In alternative embodiments, the casting mold 102 may be of any type and shape suitable for casting molten metal 106.

[0026] In various embodiments, the mold 102 may additionally or alternatively assist in cooling the molten metal 106 to form an ingot 108. In a non-limiting example, the mold 102 is a water-cooled mold. For example, the mold 102 may include a cooling system that uses one or more of air, glycol, or any suitable cooling medium. In various embodiments, the casting mold 102 may have heated walls to slow the cooling of the mold walls (for example, an Ohno Continuous Caster mold may be used).

[0027] Ingot 108 may be formed from molten metal 106 cooled by the walls of mold 102. For example, molten metal 106 may be placed into mold 102 and begin to solidify to form ingot 108. Bottom block 114 may be gradually lowered while additional molten metal 106 is added to the top of the mold 102, lengthening the ingot 108.

[0028] Molten metal 106 and/or ingot 108 may be formed from any metal or combination of metals capable of being heated to a melting point. In a non-limiting example, molten metal 106 and/or ingot 108 includes aluminum. In various embodiments, molten metal 106 and/or ingot 108 may include iron, magnesium, or a combination of metals.

[0029] As mentioned above, molten metal 106 may be placed into one or more molds 102 via one or more launders 104 located adjacent to the mold. The launders 104 may include one or more openings for placing molten metal 106 into one or more molds 102. In various embodiments, the launder 104 may be located over one or more molds 102 and place the molten metal 106 into one or more molds 102 through one or more holes. The trough 104 can be of any size and shape suitable for containing and distributing molten metal 106. As shown, the trough 104 is rectangular in shape with a U-shaped channel for containing the molten metal 106. In some embodiments, the trough 104 can be any suitable size and shape for placing molten metal 106 into one or more molds 102.

[0030] In various embodiments, the trough 104 may include a flow control device 116. Flow control device 116 may control the rate of flow of molten metal 106 from launder 104 into one or more molds 102. As described below with respect to FIG. 2, flow control device 116 may include a pin located in the opening to control the flow of molten metal 106 into one or more molds 102.

[0031] One or more cameras 110 may be located in the foundry environment to acquire or detect optical data. In various embodiments, cameras 110 may be positioned to detect optical data related to one or more molds 102. Cameras 110 may be or include optics capable of acquiring still or moving images, thermal images, infrared images, x-rays, or any suitable optical data. In various embodiments, cameras 110 may send optical data to computer system 112 for processing. In some embodiments, cameras 110 may be or include components that allow the cameras to process some or all of the optical data.

[0032] The cameras 110 may have a field of view 118 that includes at least a portion of the mold 102. In some embodiments, the cameras 110 may be movable or move to change the field of view 118. For example, cameras 110 may be rotated to detect optical data associated with two adjacent molds 102. Camera 110 may be positioned opposite one or more molds 102 or otherwise have a field of view 118 including at least a portion of the mold 102. In various In embodiments, a camera 110 is located above the mold 102 with a field of view 118 that includes at least a portion of the top portion of the mold 102. The camera 110 may additionally or alternatively be located below the mold 102 with a field of view that includes at least a portion of the bottom portion casting mold 102.

[0033] In various embodiments, cameras 110 may be positioned in any suitable orientation to have a field of view 118 that includes the casting environment and/or any suitable component located in or adjacent to the casting environment. For example, cameras 110 may have a field of view 118 that includes the casting medium and a portion of the mold 102 located in the casting medium. Chambers 110 may be located within the casting environment or located outside the casting environment. In additional embodiments, the orientation of the chambers 110 can be adjusted to include the casting medium and/or any suitable component located in or adjacent to the casting medium.

[0034] The monitoring system 100 may include multiple cameras 110 operating together. Multiple cameras 110 may be arranged to have adjacent or overlapping fields of view 118. For example, two cameras 110 may be mounted at different heights above the mold 102 and may have overlapping fields of view 118 of the mold 102. As another example, two or more cameras 110 may be mounted such that each camera 110 has a field of view 118 of a portion of one sides of the mold 102. Each field of view 118 may be combined to form an image of the entire side of the mold 102 or other aggregate areas of interest.

[0035] Computer system 112 may receive optical data from cameras 110. Computer system 112 may include hardware and software for executing computer-executable commands. For example, computer system 112 may include memory, processors, and an operating system for executing computer-executable instructions (FIG. 4). The computer system 112 may have hardware or software configured to communicate with other devices through a wired connection or a wireless connection (eg, Bluetooth). The computer system 112 may be associated with one, some combination, or all of the flow control devices 116, the chamber 110, or any other suitable components associated with the foundry environment.

[0036] In various embodiments, computer system 112 may be located in a single physical location. For example, the computer system 112 may be hardware and software located in the same manufacturing facility as one or more molds 102 and coupled to the cameras 110 via a local communications network (e.g., Wi-Fi or Bluetooth). In some embodiments, one or more computer systems 112 may be located at multiple physical locations and communicated with cameras 110 via long-range communications (eg, the Internet, radio waves, or satellites). For example, computer system 112 may be a cloud computing system including any number of Internet-connected computing components.

[0037] The computer system 112 may include hardware and software configured to perform the following steps: receiving optical data from the camera(s) 110, analyzing the received data, and generating operating commands for the casting operation. Some or all of these steps may be performed by a single computer system 112 or by multiple computer systems.

[0038] In various embodiments, the computer system 112 may include hardware and software configured to perform the steps of placing molten metal 106 into the mold 102 as part of a casting operation, receiving optical data associated with the ingot 108, controlling the whipstock 510, determining separating the ingot 108 from the lower block 114 and generating operating instructions for the casting operation.

[0039] In various embodiments, computer system 112 may provide an alert to a user based on optical data received from cameras 110. For example, computer system 112 may activate an alert in response to optical data. The warning signal may correspond to or include a bell, light, siren, display, speaker, or any other object capable of attracting the attention of the user or system and/or communicating information to the user or system.

[0040] Other actions may be proposed in addition to or instead of activating the alert. In various embodiments, a change in the flow of molten metal 106 into one or more molds 102 may be introduced in conjunction with or in lieu of alarm activation. For example, the flow control device 116 may be controlled to increase, decrease, or otherwise change the flow rate, volume, or other characteristics of the flow of molten metal 106 into the mold 102. In various embodiments, an alert may additionally or alternatively be displayed, logged, sent, or otherwise communicated to the user or another aspect of the system (for example, may also be independent of or in combination with activation of an alarm and/or change in the flow of molten metal 106).

[0041] With reference to FIG. 2 is a cross-sectional view of a portion of the monitoring system 100 shown in FIG. 1. The control system portion 100 includes a mold 102, a chamber 110, and a chute 104. The chute 104 may include a flow control device 116 for controlling the flow of molten metal from the chute to the mold 102. The flow control device 116 may include a pin 202 located in hole 204. Pin 202 may be attached to motor 206 to move the pin relative to hole 204.

[0042] The pin 202 may be located in the hole 204 of the groove 104. The hole 204 and/or the pin 202 may be conical in shape such that downward movement of the pin relative to the hole reduces the annular space between the pin and the hole. The pin 202 may be raised and/or lowered to control the flow of molten metal 106 from the spout 104. For example, the pin 202 may be raised to increase the annular space between the pin and the hole 204, increasing the flow of molten metal 106 from the spout 104 (e.g., as shown in solid lines ). In addition, the pin 202 can be lowered to reduce the annular space between the pin and the hole 204, reducing and/or stopping the flow of molten metal 106 from the spout 104 (eg, as shown in dotted lines).

[0043] The pin 202 can be raised and/or lowered by the motor 206. In various embodiments, the motor 206 can be coupled to the computer system 112 to automatically raise and/or lower the pin 202. In various embodiments, the pin 202 can be raised and/or lower manually. In some examples, manual raising and/or lowering of pin 202 may be suggested by computer system 112. In some embodiments, pin 202 may be automatically raised and/or lowered to maintain the level of molten metal 106 in mold 102 within a threshold range. The pin 202 may additionally or alternatively be automatically raised and/or lowered in response to detection of a gap between the ingot 108 and the lower block 114. In addition, the pin 202 may be automatically raised and/or lowered in response to the detection of one or more of a leak in the mold, cracks in the mold, dust on the mold, rust on the mold, misalignment of the mold, moisture in the mold, metal in the mold, platen snagging, platen position, platen misalignment and/or cooling system failure.

[0044] In various embodiments, the pin 202 can be raised and/or lowered (for example, the pin can move in a pulsating manner) depending on one or more states of the molten metal 106 and/or the mold 102. For example, the pin 202 can be raised and lowered in response to molten metal 106 being pulled away from the mold 102. In some embodiments, the pin 202 may be raised and lowered at regular intervals to control the flow of molten metal 106 into the mold 102. The pulsating movement of the pin 202 may cause the molten metal 106 flowing into the mold 102 will disrupt the surface tension of the molten metal in the mold 102. Disturbing the surface tension of the molten metal 106 in the mold 102 may cause the molten metal to flow more easily across the surface of the molten metal in the mold. In additional embodiments, the flow control device 116 may additionally or alternatively include a valve, stopper, funnel, or other suitable structure.

[0045] With reference to FIG. 3 shows an example of a field of view 118 of a camera 110. The field of view 118 may include the walls of a mold 102, molten metal 106, and/or an ingot 108. As shown in the example of FIG. 3, the viewing field 118 includes one side of the mold 102 (e.g., the top side) and the entire perimeter of that side of the mold 102. However, the viewing field 118 may include a sub-perimeter of the mold 102, portions of multiple molds, multiple sides of the mold molds 102 or multiple sides of multiple molds.

[0046] As an example, field of view 118 is depicted divided into four quadrants (eg, I, II, III, IV). However, the field of view 118 may include more or fewer quadrants. One camera 110 may have a field of view 118 that includes all four quadrants. However, one camera 110 may have a field of view 118 that corresponds to one quadrant or a subset of quadrants. Additionally or alternatively, one camera 110 may have a field of view 118 that corresponds to a combination of quadrants. In some embodiments, a single camera 110 may have multiple fields of view 118 (eg, each quadrant is a separate field of view 118) between which camera 110 can switch. For example, the movable camera 110 may switch between fields of view 118 as the camera 110 rotates around the top of the mold 102. In various embodiments, the quadrants may include a label corresponding to the coordinates of locations on the ingot 108 and/or mold 102.

[0047] In FIG. 4 illustrates an exemplary computer system 400 for use with the monitoring system 100 shown in FIG. 1. In various embodiments, computer system 400 includes a controller 410 that is digitally implemented and programmable using conventional computer components. The controller 410 may be used in connection with certain examples (eg, including equipment such as that shown in FIG. 1) to perform the processes of such examples. The controller 410 includes a processor 412 that may execute code stored on a tangible computer-readable medium in a storage device 418 (or elsewhere, such as, among other media, a portable medium, a server, or the cloud) to enable the controller to execute 410 receiving and processing data, actions, and/or control of hardware components, as shown in FIG. 1. The controller 410 can be any device that can process data and execute code, which is a set of instructions to perform actions, such as controlling industrial equipment. By way of non-limiting examples, controller 410 may take the form of a digitally implemented and/or programmable PID controller, a programmable logic controller, a microprocessor, a server, a desktop or laptop personal computer, a portable personal computer, a portable computing device, and a mobile device.

[0048] Examples of processor 412 include any desired processing circuit, application-specific integrated circuit (ASIC), programmable logic, state machine, or other suitable circuit. Processor 412 may include one processor or any number of processors. Processor 412 may access code stored in memory 418 via bus 414. Memory 418 may be any non-transitory computer-readable medium capable of materially implementing the code, and may include electronic, magnetic, or optical devices. Examples of storage device 418 include random access memory (RAM), read-only memory (ROM), flash memory, floppy disk, CD-ROM, digital video device, magnetic disk, ASIC, configured processor, or other storage device.

[0049] Instructions may be stored in memory 418 or processor 412 as executable code. The instructions may include processor-specific instructions generated by a compiler and/or interpreter based on code written in any suitable programming language. The commands may take the form of an application that includes a number of settings, parameters, and programmed steps that, when executed by the processor 412, allow the controller 410 to monitor and control various components of the control system 100. For example, the commands may include commands for a computer vision application.

[0050] The controller 410 shown in FIG. 4 includes an input/output interface 416 through which controller 410 can communicate with devices and systems external to controller 410, including components such as flow control device 116 or camera 110. The input/output (I/O) interface 416 can also receive input from other external sources as needed. Such sources may include control panels, other human-machine interfaces, computers, servers, or other equipment that may, for example, send commands and parameters to the controller 410 to control its performance and operation; store and facilitate programming of applications that allow the controller 410 to execute commands in those applications to control various components during the casting process; and other data sources necessary or useful to the controller 410 in performing its functions. Such data may be transmitted to input/output (I/O) interface 416 via a network, wired link, wireless link, bus, or other desired manner.

[0051] With reference to FIG. 5A and 5B show various fields of view 118 of cameras 110 in accordance with various embodiments. In fig. 5A is a front view of the mold 102, ingot 108, bottom block 114, and various view fields 118 that may be used as part of the inspection system 100, and FIG. 5 V is shown as a side view. Fields of view 118 may be obtained from a single camera 110 or may be obtained from multiple cameras. Review fields 118 may include some or all of the following: mold 102, ingot 108, and/or bottom block 114. For example, review fields 118 may include a portion of ingot 108 and bottom block 114 (e.g., 118A and 118B) or mold 102, ingot 108, and bottom block 114 (eg, 118C). The view fields 118 may provide monitoring of the ingot 108 and/or the bottom block 114. For example, the view fields 118 may include a portion of the bottom 502 of the ingot 108 and/or the top 504 of the bottom block 114. In various embodiments, the bottom block 114 may be lowered from using a mechanism 512. The mechanism 512 may be or include a lift (eg, a hydraulic lift). The mechanism 512 may be controlled (eg, by a computer system 112) to lower the lower block 114. The mechanism 512 may lower the lower block 114 at a constant speed, however, the lower block may be lowered at a variable speed.

[0052] As shown in FIG. 5A and 5B, the lower portion 502 of the ingot 108 may be separated from the upper portion 504 of the lower block 114. The separation may be detected and/or received as optical data by the cameras 110. Separation may be caused by cooling of the ingot 108. Cooling of the ingot 108 may cause the bottom 502 of the ingot 108 to curl, leaving a gap between the bottom of the ingot and the top 504 of the lower block 114. Information about the gap height can enable the determination of an appropriate cooling rate for the ingot 108. The cooling rate of the ingot 108 can be used to control the casting process. For example, the lowering speed of the lower block 114 can be adjusted based on the cooling rate.

[0053] The cameras 110 can measure the gap between the bottom 502 of the ingot 108 and the top 504 of the bottom block 114. Measuring the gap using the cameras 110 provides a gap measurement without placing components on the ingot 108, the bottom block 114, and/or the mold 102. Additionally, gap measurement using cameras 110 allows the operator to measure gap without entering the casting environment. In some embodiments, the gap may be from 0.25 cm to 10.16 cm (0.1 inch to 4 inches), however, the gap can be any suitable distance.

[0054] In various embodiments, cameras 110 may be or include a thermal imaging camera and/or an infrared camera. Field of view 118 may detect the temperature and/or thermal properties of components located within the field of view. In some embodiments, a black light may be used in combination with neon crayons to assist in gap measurement. For example, bar 108 and/or bottom block 114 may be marked with neon chalk that is illuminated with a black light. Cameras 110 may detect and/or receive an image of the neon chalk as optical data.

[0055] With reference to FIG. 6A and 6B, one or more features of the casting system may overlap the fields of view 118. For example, water 506 may flow along one or more sides of the ingot 108 between the ingot and the chambers 110. The water 506 may obscure some or all of the fields of view 118. Water 506 may flow from one or more water sources 508 . Water sources 508 may cause water to flow 506 through the ingot 108. In some embodiments, water sources 508 may be coupled to the mold 102 to cause water 506 to flow through the mold. Water 506 flowing through the mold 102 may flow from the bottom of the mold 102 down one or more sides of the ingot 108. In various embodiments, the steam 514 may additionally or alternatively cover the fields of view 118. Steam 514 may be generated from water 506 heated during the casting process. Steam 514 may interfere with one or more cameras 110 being able to detect optical data associated with ingot 108 and/or bottom block 114. Cameras 110 may be or include a thermal imaging camera that can be used to detect thermal data associated with ingot 108 and/or bottom block 114. The thermal imaging camera may send thermal data to computer system 112. Infrared data may be used to generate an outline and/or profile of the edge of ingot 108 and/or bottom block 114.

[0056] In various embodiments, the diverter 510 may divert water 506 and/or steam 514. The water 506 may be diverted from a portion of the ingot 108. The diverted water 506 and/or steam 514 may allow cameras 110 (e.g., a thermal imaging camera) to detect thermal data , associated with the ingot 108 and/or the lower block 114, with minimal interference from hot water and/or steam. For example, when removing water 506 and/or steam 514, cameras 110 may measure the distance between the bottom 502 of the ingot 108 and the top 504 of the bottom block 114. The diverter 510 may be coupled to the mold 102 and/or may be built into the mold 102. For example, the diverter 510 may be or include a plug located in the mold 102 that prevents water 506 from flowing through the mold 102. The diverter 510 may be additionally or alternatively attached to the outside of the mold 102. For example, the diverter 510 may be is a device located below the mold 102 that blocks and/or diverts water 506 after it flows through the mold. The diverter 510 may be or include an air ejector, a fan, a sheet, or a plug.

[0057] With reference to FIG. 7 is a flowchart illustrating an exemplary method 700 of using the monitoring system 100. Some or all of the blocks of method 700 (or any other methods described herein, or variations and/or combinations thereof) may be executed under the control of one or more computer systems configured with executable instructions, and may be implemented in code (eg , executable instructions, one or more computer programs, or one or more applications) executed together on one or more processors, hardware, or combinations thereof. The code may be stored in a computer-readable storage medium, such as a computer program including a plurality of instructions executable by one or more processors. The computer-readable storage medium may be non-volatile. In addition, unless otherwise indicated, the steps shown in the methods do not necessarily have to be performed in the order shown and/or some steps may be omitted in the embodiments.

[0058] Method 700 at block 702 may include placing metal, such as molten metal 106, into one or more molds, such as mold 102. Molten metal 106 may be placed into mold 102 via a launder 104, as described. in this document. The launder 104 may place molten metal 106 into the mold 102 through one or more openings in the launder 104. The amount or flow rate of the molten metal 106 entering the mold 102 can be controlled by controlling the flow control device 116. Molten metal 106 may enter mold 102 through an opening in mold 102. Molten metal 106 contained in mold 102 may contact one or all walls of mold 102. The temperature of molten metal 106 may decrease after entering mold 102. and the molten metal 106 may cool to become a solid or semi-solid ingot 108.

[0059] Method 700 at block 704 may include receiving optical data associated with the ingot 108. The optical data may be acquired or detected using cameras, such as cameras 110. Cameras 110 may have a field of view 118 that includes a casting mold 102, ingot 108, and bottom block 114. In various embodiments, field of view 118 includes a portion of ingot 108 (e.g., an edge) and bottom block 114. Multiple cameras 110 may be arranged to have overlapping fields of view 118, wherein a single camera can have multiple fields of view, or multiple cameras can have separate fields of view. Cameras 110 may be positioned to receive or detect optical data associated with the mold 102 and/or molten metal 106. For example, cameras 110 may receive optical data associated with the gap between the ingot 108 and the lower block 114. The computer system 112 may receive the optical data from cameras 110 and/or from a database. For example, computer system 112 may receive optical data from a database containing optical data associated with various molds. In various embodiments, cameras 110 may be or include thermal imaging and/or infrared cameras. Thermal and/or infrared cameras may be able to detect optical data that includes a thermal and/or infrared profile of the ingot 108 and/or bottom block 114. Thermal and/or infrared cameras may be able to detect optical data that may otherwise be invisible for cameras 110. For example, ingot 108 and/or bottom block 114 may be obstructed from the view of a “conventional” camera (e.g., one that receives and/or processes light visible to the human eye), but a thermal or infrared camera may be able to detect thermal and/or infrared profile of the ingot and/or lower block. For example, a thermal imaging camera may detect elevated levels of heat from the ingot 108 and thus “see through” or not be blocked by an intermediate layer of water (for example, which may be at a significantly lower temperature than the ingot) and/or an intermediate layer of steam. The thermal and/or infrared profile may include some or all of the optical data included in the image captured and/or detected by the non-thermal imaging camera.

[0060] The method 700 at block 706 may include operating a diverter 510. The diverter 510 may be configured to remove water 506 and/or steam 514 from an area that is detected by the cameras 110. For example, the diverter 510 may remove water 506 and/or par 514 from field 118 review. As an illustrative example, the diverter 510 may include an air ejector that is configured to direct water 506 and/or steam 514 away from the detection area. In some embodiments, deflector 510 may be activated before optical data is received and deactivated after optical data is detected. However, the diverter 510 may reject water 506 and/or steam 514 when no optical data is detected

[0061] Method 700 at block 708 may include determining whether ingot 108 has separated from lower block 114. For example, using optical data from cameras 110, computer system 112 may determine whether ingot 108 has separated from lower block 114. Computer system 112 may determine separation distance from the bottom 502 of the ingot 108 and the top 504 of the lower block. In various embodiments, separation of the ingot 108 and the lower block 114 can be determined by comparing the contours and/or profiles of the edge of the ingot 108 and/or the lower block 114 detected by the camera 110 (eg, a thermal imaging camera). For example, the bottom block 114 may have a very high temperature gradient and the edge profile will be different from the edge profile of the ingot 108. The distance between the ingot 108 and the bottom block 114 can be determined by measuring the distance between the edge profiles.

[0062] Method 700 at block 710 may include generating operating instructions for a casting operation. Work commands may include commands to make changes to the casting process or may include commands to continue the casting operation without any changes. Operating commands may be based on the separation between the ingot 108 and the lower block 114. For example, depending on the distance between the ingot 108 and the lower block 114, the casting process can be adjusted. In various embodiments, operating commands may include adjusting the speed of lowering the lower block 114, the flow rate of molten metal 106 into the mold 102, the amount of water 506 flowing into the mold, the duration of activation of the diverter 510, or any suitable commands. In various embodiments, operating commands may include commands to the user that, if not executed, cause the commands to be automatically executed by the computer system 112. For example, the commands may prompt the user to adjust one or more parameters associated with the casting of ingot 108, and, if the user does not execute commands in a timely manner, the computer system 112 may automatically adjust the specified parameters.

[0063] All patents, publications and abstracts cited above are incorporated herein by reference in their entirety. The previous description of the embodiments, including illustrative 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 precise forms described. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

ASPECTS

[0064] Aspect 1 is a mold control system including: a mold defining an opening for receiving molten metal and including a lower block that is lowered while casting molten metal into an ingot; a chute configured to supply molten metal into the mold; a water source configured to supply water to the mold; a diverter configured to drain water from part of the ingot; a camera having a field of view including at least that portion of the ingot from which water has been drained, the camera being configured to obtain optical data associated with the ingot; and a controller including a processor configured to execute instructions stored in a non-volatile computer readable medium in a storage device, the controller causing the processor to perform processor operations including: receiving optical data associated with the ingot portion or the lower block portion; determining, based on optical data, whether a portion of the ingot has separated from a portion of the lower block; and generating operating commands to cast the molten metal into an ingot if it is determined that separation has occurred.

[0065] Aspect 2 is the system of aspect(s) 1 (or any other preceding or subsequent aspects alone or in combination), wherein the processor operations further include: determining based on whether a portion of the ingot has separated from the underlying block, the distance between part of the ingot and the lower block; and generating operating commands based on at least a distance between the portion of the ingot and the lower block.

[0066] Aspect 3 is the system of aspect(s) 2 (or any other preceding or subsequent aspects individually or in combination), wherein the operating commands include commands for at least one of adjusting the speed of lowering the lower block, adjusting the speed flow of molten metal or regulation of the flow rate of water.

[0067] Aspect 4 is the system of aspect(s) 1 (or any other preceding or subsequent aspects alone or in combination), wherein the processor operations further include, prior to receiving optical data, controlling a diverter to remove water from a portion of the ingot .

[0068] Aspect 5 is the system of aspect(s) 1 (or any other preceding or subsequent aspects alone or in combination), wherein the optical data includes at least one of an image or an infrared profile.

[0069] Aspect 6 is the system of aspect(s) 1, which comprises a flow control device configured to control the flow rate of molten metal from a spout into a mold for casting molten metal into an ingot, water flowing from the mold during casting molten metal into an ingot, and the camera field of view further includes at least a lower block portion and a portion of the ingot and is configured to obtain optical data associated with the ingot portion or the lower block portion, and wherein the processor operations further include: obtaining the first optical data associated with the ingot part; generating a profile associated with the ingot portion based on at least the first optical data; comparison of the profile with the base profile; and determining, based on the comparison, whether a portion of the ingot has separated from the lower block.

[0070] Aspect 7 is the system of aspect(s) 6 (or any other preceding or subsequent aspects alone or in combination), wherein the camera includes an infrared camera and the optical data associated with the ingot includes an infrared profile associated with part of the lower block or part of the ingot.

[0071] Aspect 8 is the system of aspect(s) 6 (or any other preceding or subsequent aspects alone or in combination), wherein the operating instructions include instructions for controlling a flow control device to regulate the rate of flow of molten metal into the mold , regulating the speed of water flow into the mold or regulating the speed of movement of the lower block.

[0072] Aspect 9 is the system of aspect(s) 6 (or any other preceding or subsequent aspects alone or in combination), wherein determining whether separation of a portion of the ingot from a portion of the lower block has occurred includes determining the separation distance between part of the ingot and part of the lower block.

[0073] Aspect 10 is the system of aspect(s) 9 (or any other preceding or subsequent aspects alone or in combination) wherein the separation distance is in the range of 0.25 cm to 10.16 cm (0 .1 inches to 4 inches).

[0074] Aspect 11 is the system of aspect(s) 6 (or any other preceding or subsequent aspects alone or in combination), further including a diverter coupled to the mold and configured to drain water away from a portion of the ingot.

[0075] Aspect 12 is the system of aspect(s) 11 (or any other preceding or subsequent aspects alone or in combination), wherein the diverter comprises at least one of an air ejector, a sheet, or a plug.

[0076] Aspect 13 is the system of aspect(s) 6 (or any other preceding or subsequent aspects alone or in combination), wherein the processor operations further include: receiving second optical data associated with the ingot portion; updating a profile associated with a portion of the ingot based on at least the second optical data; comparison of the updated profile with the base profile; and determining, based on the comparison, whether a portion of the ingot has separated from the lower block.

[0077] Aspect 14 is the system of aspect(s) 6 (or any other preceding or subsequent aspects alone or in combination), wherein comparing a profile to a base profile includes comparing an infrared profile of a portion of the ingot to an infrared profile of a lower block.

[0078] Aspect 15 is a method of controlling a casting mold, comprising: initiating a casting operation using a casting system including a casting mold including a bottom block and a trough, the casting operation comprising: allowing a flow of molten metal into the mold; ensuring the flow of water into the mold; cooling the molten metal to form an ingot; and lowering the lower block; drainage of water from part of the ingot; obtaining, using the camera, first optical data associated with the part of the ingot; comparison of the first optical data with the base profile; and determining, based on the comparison, whether a portion of the ingot has separated from the lower block.

[0079] Aspect 16 is the method of aspect(s) 15 (or any other preceding or subsequent aspects alone or in combination), further comprising: determining a separation distance between the ingot portion and the bottom block; and generating, based on the separation distance, operating commands for the casting operation.

[0080] Aspect 17 is the method of aspect(s) 16 (or any other preceding or subsequent aspects alone or in combination), wherein adjusting the casting operation includes changing the flow rate of molten metal into the mold, changing the flow rate of water into mold or adjusting the lowering of the lower block.

[0081] Aspect 18 is the method of aspect(s) 15 (or any other preceding or subsequent aspects alone or in combination), further comprising: obtaining, with a camera, second optical data associated with a portion of the ingot; comparing the second optical data with the base profile; and determining, based on the comparison, whether a portion of the ingot has separated from the lower block.

[0082] Aspect 19 is the method of aspect(s) 15 (or any other preceding or subsequent aspects alone or in combination), wherein obtaining the first optical data includes obtaining infrared data associated with the ingot.

[0083] Aspect 20 is the method of aspect(s) 15 (or any other preceding or subsequent aspects alone or in combination), wherein removing water from a portion of the ingot includes controlling an air ejector.

Claims (42)

1. A system for inspecting a casting mold forming an opening for receiving molten metal and containing a lower block that is lowered during the casting of molten metal into an ingot, containing a chute configured to supply molten metal into the mold, a water source configured to supply water to the mold, a diverter configured to drain water from part of the ingot, a camera configured to obtain optical data associated with the ingot, having a field of view including at least a portion of the ingot from which water has been removed, and a controller including a processor configured to execute instructions stored on a non-volatile computer readable medium in a storage device, wherein the controller is configured to cause the processor to perform operations including receiving optical data associated with a portion of the ingot or a portion of a lower mold block, determining based on the optical data whether part of the ingot has separated from part of the lower block of the casting mold and generation of work commands to carry out the process of casting molten metal into the ingot when determining whether the separation has occurred. 2. The system according to claim 1, characterized in that the processor is configured to perform the operations of determining the distance between the part of the ingot and the lower block when separating the part of the ingot from the lower block of the mold and generating operating commands based on at least the distance between the part of the ingot and the lower block. 3. The system according to claim 2, wherein the operating instructions generated by the processor are instructions that provide at least one of regulating the lowering speed of the lower mold block, regulating the molten metal flow rate, or regulating the water flow rate. 4. The system according to claim 1, characterized in that the processor is configured to, before receiving optical data, carry out operations to control the diverter to drain water from part of the ingot. 5. The system according to claim 1, characterized in that the optical data is at least one of an image or an infrared profile of the edge of the ingot and/or the lower block of the mold. 6. The system according to claim 1, characterized in that the chute is equipped with a flow control device configured to regulate the flow rate of molten metal from the chute into the mold for casting the molten metal into an ingot during said casting when water enters the ingot from the mold , wherein the camera is configured with a field of view including at least a portion of the lower mold block and a portion of the ingot, allowing for the acquisition of optical data associated with the ingot portion or the lower mold portion, wherein the processor is configured to perform the following operations: obtaining the first optical data associated with a part of the ingot, generating an edge profile of the ingot portion and/or a lower mold block associated with the ingot portion based on at least the first optical data, comparing the generated profile with the base profile and determining, based on the comparison, the separation of part of the ingot from the lower block. 7. The system according to claim 6, characterized in that it comprises an infrared camera as a camera, and the optical data associated with the ingot includes an infrared profile of the edge of the ingot and/or the lower mold block associated with a part of the lower mold block or part ingot. 8. The system according to claim 6, characterized in that the processor is configured to generate operating commands for casting molten metal, including operating commands for controlling a flow control device to regulate the flow rate of molten metal into the mold, operating commands for regulating the flow rate of water into the mold or operating commands to control the speed of movement of the lower block of the mold. 9. The system according to claim 6, characterized in that the processor is configured to determine the separation of a part of the ingot from a part of the lower block, including determining the separation distance between the part of the ingot and the part of the lower block. 10. The system of claim 9, wherein the separation distance between the ingot portion and the lower block portion is in the range of 0.25 to 10.16 cm (0.1 inch to 4 inch). 11. The system according to claim 6, characterized in that it is additionally equipped with a diverter connected to the casting mold, configured to drain water from part of the ingot. 12. The system according to claim 11, characterized in that the diverter contains at least one of an air ejector, a sheet or a plug. 13. The system according to claim 6, characterized in that the processor is configured to perform additional operations, including: receiving second optical data associated with the ingot portion, updating the edge profile of the ingot portion and/or lower mold block associated with the ingot portion based on at least the second optical data, comparison of the updated edge profile of part of the ingot and/or lower block of the mold with the base profile and determining, based on the comparison mentioned, the separation of part of the ingot from the lower block. 14. The system according to claim 6, characterized in that the processor is configured to compare the profile of the edge of the ingot and/or the lower block of the casting mold with the base profile of the edge of the ingot and/or the lower block of the casting mold, including comparing the infrared profile of the edge of the part of the ingot with the infrared profile edges of the lower block. 15. A method of controlling a casting mold, comprising initiating a casting operation in a casting system comprising a casting mold with a lower block and a chute, ensuring the flow of molten metal into the mold, ensuring the flow of water into the mold, cooling the molten metal to form an ingot, lowering the lower block, drainage of water from part of the ingot, obtaining, using the camera, first optical data associated with the part of the ingot; comparison of the first optical data with the basic profile of the edge of the ingot and/or the lower block of the mold, determining, based on the above comparison, the separation of part of the ingot from the lower block of the casting mold. 16. The method according to claim 15, characterized in that it determines the separation distance between the part of the ingot and the lower block and generates operating commands for the casting operation based on the specified separation distance. 17. The method of claim 16, wherein adjusting the casting operation includes changing the flow rate of molten metal into the mold, changing the flow rate of water into the mold, or adjusting the lowering of the lower block of the mold. 18. The method according to claim 15, characterized in that it further includes: obtaining, using a camera, second optical data associated with a part of the ingot, comparing the second optical data with the base profile of the edge of the ingot portion and/or lower mold block; and determining, based on the above comparison, the separation of part of the ingot from the lower block of the casting mold. 19. The method according to claim 15, characterized in that the acquisition of the first optical data is carried out by obtaining infrared data associated with a portion of the ingot. 20. The method according to claim 15, characterized in that the removal of water from part of the ingot is ensured by controlling the air ejector.