WO2017201059A1 - Système et procédé d'ajustement des composants de coulée continue - Google Patents

Système et procédé d'ajustement des composants de coulée continue Download PDF

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Publication number
WO2017201059A1
WO2017201059A1 PCT/US2017/032921 US2017032921W WO2017201059A1 WO 2017201059 A1 WO2017201059 A1 WO 2017201059A1 US 2017032921 W US2017032921 W US 2017032921W WO 2017201059 A1 WO2017201059 A1 WO 2017201059A1
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WO
WIPO (PCT)
Prior art keywords
sensor
cast strip
casting
alloy
adjustment
Prior art date
Application number
PCT/US2017/032921
Other languages
English (en)
Inventor
Leland Lorentzen
Original Assignee
Golden Aluminum Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Golden Aluminum Company filed Critical Golden Aluminum Company
Publication of WO2017201059A1 publication Critical patent/WO2017201059A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/16—Controlling or regulating processes or operations
    • B22D11/22—Controlling or regulating processes or operations for cooling cast stock or mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/001—Continuous casting of metals, i.e. casting in indefinite lengths of specific alloys
    • B22D11/003—Aluminium alloys
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N13/00—Investigating surface or boundary effects, e.g. wetting power; Investigating diffusion effects; Analysing materials by determining surface, boundary, or diffusion effects
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
    • G01N21/8901—Optical details; Scanning details
    • G01N21/8903—Optical details; Scanning details using a multiple detector array
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
    • G01N21/8914—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the material examined
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/07—Analysing solids by measuring propagation velocity or propagation time of acoustic waves
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
    • G01N29/4409—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison
    • G01N29/4427—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison with stored values, e.g. threshold values
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
    • G01B21/02—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness
    • G01B21/08—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness for measuring thickness
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N19/00—Investigating materials by mechanical methods
    • G01N19/08—Detecting presence of flaws or irregularities
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N2021/8411—Application to online plant, process monitoring
    • G01N2021/8416—Application to online plant, process monitoring and process controlling, not otherwise provided for
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
    • G01N21/8914—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the material examined
    • G01N2021/8918—Metal
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/02—Indexing codes associated with the analysed material
    • G01N2291/028—Material parameters
    • G01N2291/02854—Length, thickness

Definitions

  • the disclosure relates generally to continuous casting and particularly to automated or partially automated continuous casting systems.
  • Continuous casting uses traveling endless molds (e.g., rolls, belts, and/or wheels) having zero or substantially zero relative movement between the mold and casting surfaces. Most moving molds provide a high cooling rate due to a very small air gap between the mold and casting surface.
  • Figure 1 shows a prior art block caster 100.
  • a molten metal poured into a launder 104 is fed from a headbox or tundish 108 through a ceramic nozzle 1 12 into the space between opposing and counter-rotating chains 1 14a and 1 14b of metal chilling blocks 1 18 traveling on caterpillar-like tracks 122.
  • the blocks 1 18 are cooled by chillers 126, which in turn cool and solidify the melt in the space between the opposing chilling blocks.
  • Adjacent blocks contact each other to prevent or inhibit penetration of liquid metal into any inter-block gap to avoid or minimize the formation of block joints in the surface of the cast strip 130.
  • the cast strip 130 is pulled out by a withdrawal unit (not shown) synchronized with the sprocket drive 134 of the blocks.
  • a withdrawal unit not shown
  • a surface impression of the joint between the blocks known as a block joint
  • movement of adjacent blocks from heating and cooling cycles in response to contact with molten metal can form on the cast strip 130 due to relative position or (e.g., the chilling block is made level before startup but is rarely perfectly flush and there is movement during caster operation) movement of adjacent blocks from heating and cooling cycles in response to contact with molten metal.
  • the cast strip adjacent to the face of a chilling block (and away from the inter-block joints) generally has significantly fewer, if any, surface irregularities.
  • FIG. 2 shows a prior art twin-belt caster 200.
  • Molten metal is fed from the ceramic nozzle 112 through the gap between two counter-rotating belts 204a and 204b under tension.
  • the belts are cooled by water jets 208 from a side opposite the surface contacting the cast strip 130.
  • the cooled belts cool and solidify the melt between the belts.
  • Back-up rolls 212 maintain a substantially planar surface of the belt contacting the cast strip 130.
  • the cast strip 130 is pulled out by a withdrawal unit (not shown) synchronized with the sprocket drive 216 of the blocks.
  • a common surface defect in cast strip manufactured by belt casters is an impression of the belt seam.
  • a typical belt seam impression has a height of up to about 125 microns, more typically from about 5 to about 100 microns, and more typically from about 10 to about 75 microns above the surrounding surface of the cast strip and can render the cast strip unsuitable for many applications, including automotive exterior panels due to post-painting visibility.
  • continuous casting systems include without limitation single-roll casters, twin-roll casters, and rotary casters.
  • the present disclosure is directed to automated monitoring and/or adjustment of a casting system or assembly.
  • a casting system can include:
  • a nozzle to provide a molten metal or metal alloy
  • a casting assembly to cool and mold the molten metal or metal alloy to form a cast strip
  • a microprocessor executable control system to determine an adjustment amount and/or direction of a casting assembly component based on the identified surface defect and at least one of: (a) provide the adjustment amount and/or direction to an operator for adjustment of the casting assembly component and (b) command that the casting assembly component be adjusted by the adjustment amount and/or direction.
  • the casting assembly can include a block caster.
  • the casting assembly component can be an adjustment point on a chilling block.
  • the surface defect can be an impression of a block joint.
  • the sensor can be one of a plurality of sensors comprising first and second sensor sets. Each sensor in the first sensor set can scan a portion of an upper surface of the cast strip, and each sensor in the second sensor set can scan a portion of a lower surface of the cast strip. Each sensor in the first sensor set can oppose a corresponding sensor in the second sensor set. Each opposing pair of sensors in the first and second sensor sets can be in line with a respective adjustment point.
  • the sensor can be positioned such that the sensed defect is caused by the casting assembly component to be adjusted.
  • the sensor can be one or more of a laser radar detector, a mechanical displacement device, an imaging device, an optical 3d measuring system, or an ultrasound transducer. Commonly, the sensor is free of contact with the cast strip surface.
  • the control system can sense a defect by measuring a thickness of the cast strip and comparing the measured thickness to a predetermined thickness for the cast strip.
  • the control system can determine the adjustment amount and/or direction based on a difference between the measured and predetermined thicknesses.
  • the molten metal or alloy can be one or more of manganese, a manganese alloy, aluminum, an aluminum alloy, copper, a copper alloy, iron, and an iron alloy.
  • the casting system can also include a launder to receive the molten metal or metal alloy from a furnace and a tundish and/or headbox to receive the molten metal or metal alloy from the furnace and provide the melt to the nozzle.
  • the casting assembly can alternatively be one or more of a single-belt caster, twin- belt caster, single-roll caster, twin-roll caster, and rotary caster.
  • the casting assembly component can be one or more of a roller, belt, back-up roll, and block belt.
  • the control system can adjust one or more of the position, orientation, application force applied to the cast strip, and pressure applied to the cast strip of or by the casting assembly component.
  • the present disclosure can provide a number of advantages depending on the particular aspect, embodiment, and/or configuration.
  • the casting system can identify a cast strip surface defect and enable automatic or semi-automatic adjustment of one or more casting system components, during casting system operation, to inhibit, remove, or reduce the formation of the identified surface defect in a next casting cycle (e.g., next revolution of a roll, block or belt caster). This can eliminate not only the need for manual block adjustment but also for shutting down the casting system to reset improperly adjusted casting system components. This has the further benefit of making less expensive continuously cast strip applicable to a broader variety of applications and markets.
  • each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C", “one or more of A, B, or C" and "A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
  • each one of A, B, and C in the above expressions refers to an element, such as X, Y, and Z, or class of elements, such as Xi-Xn, Yi-Ym, and Zi-Z 0
  • the phrase is intended to refer to a single element selected from X, Y, and Z, a combination of elements selected from the same class (e.g., Xi and X2) as well as a combination of elements selected from two or more classes (e.g., Yi and Z 0 ).
  • Al alloys are alloys in which aluminum (Al) is the predominant metal.
  • the typical alloying elements are copper, magnesium, manganese, silicon, and zinc.
  • automated refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be "material”.
  • computer-readable medium refers to any storage and/or transmission medium that participate in providing instructions to a processor for execution.
  • Such a computer-readable medium is commonly tangible, non-transitory, and non-transient and can take many forms, including but not limited to, non-volatile media, volatile media, and transmission media and includes without limitation random access memory (“RAM”), read only memory (“ROM”), and the like.
  • RAM random access memory
  • ROM read only memory
  • Non-volatile media includes, for example, NVRAM, or magnetic or optical disks.
  • Volatile media includes dynamic memory, such as main memory.
  • Computer-readable media include, for example, a floppy disk (including without limitation a Bernoulli cartridge, ZIP drive, and JAZ drive), a flexible disk, hard disk, magnetic tape or cassettes, or any other magnetic medium, magneto-optical medium, a digital video disk (such as CD-ROM), any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, a solid state medium like a memory card, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read.
  • a floppy disk including without limitation a Bernoulli cartridge, ZIP drive, and JAZ drive
  • a flexible disk including without limitation a Bernoulli cartridge, ZIP drive, and JAZ drive
  • hard disk hard disk
  • magnetic tape or cassettes or any other magnetic medium
  • magneto-optical medium such as CD-ROM
  • CD-ROM digital video disk
  • any other optical medium punch cards, paper
  • a digital file attachment to e-mail or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium.
  • the computer-readable media is configured as a database
  • the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Accordingly, the disclosure is considered to include a tangible storage medium or distribution medium and prior art-recognized equivalents and successor media, in which the software
  • Computer-readable storage medium commonly excludes transient storage media, particularly electrical, magnetic,
  • continuous casting or “strand casting” refers to the process whereby molten metal is solidified into a “semifinished” billet, bloom, or slab for subsequent rolling in the finishing mills. Continuous casting is often used to cast aluminum, magnesium, and copper alloys and steel.
  • module refers to any known or later developed hardware, software, firmware, artificial intelligence, fuzzy logic, or combination of hardware and software that is capable of performing the functionality associated with that element.
  • component or composition levels are in reference to the active portion of that component or composition and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.
  • component or composition levels are in reference to the active portion of that component or composition and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.
  • Figure 1 depicts a prior art block casting system
  • Figure 2 depicts a prior art twin-belt casting system
  • Figure 3 depicts a partial top view of a block casting system according to an embodiment of this disclosure
  • Figure 4 depicts a partial side view of a block casting system according to an embodiment of this disclosure
  • Figure 5A is a top view of a chilling block according to an embodiment
  • Figure 5B is a side view of a chilling block according to an embodiment
  • Figure 6 is a flow chart of control logic according to an embodiment
  • Figure 8 graphically depicts sensor feedback.
  • FIGS. 3 and 4 depict an embodiment of a block casting system 300 according to this disclosure.
  • the block casting system has upper and lower sets 304a and 304b of chilling blocks 316 to cool and solidify the molten metal into a cast strip 130, plural sensors 308 located above and below the cast strip 130 to detect surface defects, such as block joint impressions caused by inter-block joints 320 (the solid line refers to the joint
  • 320 between adjacent chilling blocks 316 in upper set 304a and dashed lines refer to the joints 320 between adjacent chilling blocks in lower set 304b) and belt seams
  • an adjustment control module 312 in communication by control lines 324 with the sensors and adjustment components in the chilling blocks 316, to receive measurements and provide user recommendations or automatic commands to adjust the blocks 316 appropriately to substantially minimize or inhibit formation of surface defects.
  • Surface defects removed, inhibited, or otherwise reduced in frequency by the block casting system 300 can vary depending on the casting technology employed.
  • Surface defects in continuously cast strip include, for example, impressions left by block joints and belt seams, streaks, drag marks, protrusions, channels, valleys, crystallites, films (such oxide films), impurities, or combinations thereof.
  • the defects can be caused by one or more of the rollers, belts, and blocks of the caster and can be addressed by adjusting one or more of the position, orientation, application force or pressure (applied to the cast strip), and the like of the roller, belt, or block.
  • the control system can adjust the roll across the face.
  • sensors that are made up of a series of rings that measure tight spots in the cast strip, slab, or sheet.
  • a roll can be made using actuators in place of sensors to make changes in the geometry of the mold of a roll caster.
  • the roll can include a series of rings on the center shaft with adjustments from the shaft access to accommodate thickness variations across the face of the cast surface due to a variation in roll geometry or even metal temperature variations causing dimensional variation in the slab thickness.
  • each chilling block 316 in the upper and lower sets 304a and 304b of chilling blocks is positioned on one of the opposing sides of the cast strip 130 and includes multiple adjustment points or adjustment devices 328 (hereinafter “adjustment points"), typically located at or near each joint 320.
  • adjustment points 328 can be any device able to move the chilling block upwardly and/or downwardly at the adjustment point's respective location (as shown by the arrows in Figures 5A and 5B)
  • examples of adjustment points 328 include coarse and/or fine adjustment screws, differential adjusters, sub-micron adjustors, hydraulic actuators, and other adjustment mechanisms.
  • the adjustment points 328 can be distributed at selected locations in a matrix or grid pattern. Adjustment points 328a-f are laid out along line 500 and adjustment points 328g-l along parallel line 504. Pairs of adjustment points are further laid out along lines orthogonal to parallel lines 500 and 504, specifically adjustment points 329a and g are laid out along line 508, adjustment points 329b and h are laid out along line 512, adjustment points 329c and i are laid out along line 516, adjustment points 329d and j are laid out along line 520, adjustment points 329e and h are laid out along line 524, and adjustment points 329f and i are laid out along line 528.
  • each adjustment point is assigned a unique identifier relative to the other adjustment points.
  • the identifier in one embodiment has a first unique identifier "X" corresponding to an identifier of the upper or lower set of chilling blocks of which the selected chilling block 316 is a member, a second identifier "Y" (which may be non-unique relative to another chilling block in the other set of chilling blocks but is unique within the set of chilling blocks of which the selected chilling block is a member) corresponding to an identifier of the particular chilling block adjusted by the selected adjustment point, and a third identifier "Z" (which may be non-unique relative to another adjustment point in another chilling block in the upper or lower sets of chilling blocks 304a and 304b but is unique within the corresponding chilling block 316 on which the selected adjustment point is located) is an identifier corresponding to the selected adjustment point.
  • the sensors 308 can be any device able to detect surface irregularities or defects, such as block joint impressions, in the upper and/or lower surfaces of the cast strip 130.
  • Examples include a laser radar detector (which uses a laser beam 350 to determine the distance to the cast strip surface), mechanical displacement device (which measures the vertical variations in travel or movement of a wheel or other contact device with the cast strip surface), imaging device (which uses image processing to identify surface defects and other variations in cast strip surface topology, such as image processing based on the cast strip surface images captured by still pictures or video images captured as described in US 4,539,561 (which is incorporated herein by this reference)), optical 3d measuring system (which uses triangulation to determine the spatial dimensions and the geometry of the cast strip surface), and ultrasound transducer (which uses an ultrasound transducer to emit ultrasonic energy and ultrasonic time-of-flight methods to measure distance from the sensor to the cast strip surface).
  • a laser radar detector which uses a laser beam 350 to determine the distance to the cast strip surface
  • mechanical displacement device which measures the
  • Laser radar for example, can operate on the time of flight principle by sending a laser pulse in a narrow beam towards the cast strip surface and measuring the time taken by the pulse to be reflected off the target cast strip surface and returned to the sender.
  • Other laser radar distance measuring technologies include multiple frequency phase-shift (which uses an intensity modulated beam to measure the phase shift of multiple frequencies on reflection from the cast strip surface and then solves various simultaneous equations to yield a final distance measure from the sensor to the cast strip surface), frequency modulation (which use modulated laser beams, for example, with a repetitive linear frequency ramp by which the distance to be measured from the sensor to the cast strip surface is translated into a frequency offset) and interferometry (which measures changes in distance between the sensor and cast strip surface rather than absolute distances). Due to the high temperatures of the cast strip, non-contact sensors, such as laser radar, imaging devices, optical 3d measuring systems, and ultrasound systems, are generally employed.
  • each sensor has a unique (relative to the other sensors) sensor identifier.
  • the sensor identifier can be as simple as a
  • the sensor identifier can be a combination of a first indicator (indicating whether the sensor is located above or below the cast slab 130) and a second identifier indicating which sensor of the corresponding set of upper or lower sensors originated the signal).
  • the geometry of the block casting system 300 can be important.
  • the centers of the adjustment points and centers of the corresponding pair of upper and lower sensors are commonly located in or along a common plane.
  • the centers of the top row of adjustment points 328 and upper and lower sensors 308 can lie in plane 360
  • the centers of the next row of adjustment points 328 and upper and lower sensors 308 can lie in plane 364
  • the centers of the next row of adjustment points 328 and upper and lower sensors 308 can lie in plane 368
  • the centers of the next row of adjustment points 328 and upper and lower sensors 308 can lie in plane 372
  • the centers of the next row of adjustment points 328 and upper and lower sensors 308 can lie in plane 376
  • the centers of the next row of adjustment points 328 and upper and lower sensors 308 can lie in plane 378.
  • the centers of the upper and lower sets of sensors 308 can lie in a common plane 382.
  • the distance 388 between an adjustment zone 392 and measurement zone 396 can be selected such that the surface portion of the cast strip in the measurement zone at any point in time was molded by and in contact with the inter-block joint 320 of adjacent chilling blocks 318 (or chilling block 318 portion) currently in the adjustment zone. In this manner, the adjacent sets of adjustment points on either side of the inter-block joint
  • the distance 388 is typically a function of one or more of the speed of displacement of the cast strip 130, the rate of rotation of the sprocket drive 216, chilling block 316 width, and the number of chilling blocks 316 in each of the upper and lower sets of chilling blocks 304a and 304b.
  • the inter-block joints 320 of the blocks in contact with the upper surface of the cast strip 130 and adjustment points are offset in the direction of cast strip travel from the inter-block joints 320 and adjustment points of the blocks in contact with the lower surface of the cast strip 130.
  • the cast strip surface potentially containing a block joint impression from an inter-block joint in the adjustment zone alternates between the upper and lower cast strip surfaces as the cast strip moves through the measurement zone 396.
  • the upper and lower chilling blocks 316 and inter-block joints 320 move in a common direction when in contact with the cast strip.
  • control system 312 The operation of the control system 312 will now be discussed with reference to Figure 6. The discussion assumes that the block casting system 300 is operating to produce cast strip 130.
  • step 600 the control system detects a set of adjustment points for a chilling block and/or inter-block joint entering the adjustment zone (or a welded belt seam entering the adjustment zone in the case of a belt caster). This can be determined in many ways. In one technique, a position of a selected chilling block and/or inter-block joint (or a welded belt seam entering the zone in the case of a belt caster) is synchronized in computer readable memory with movement of one or both of the upper and lower sets of chilling blocks 304a and 304b (or the upper and lower belts in the case of a belt caster).
  • the locations of the other chilling block and/or inter-block joints are readily determined (as the chilling blocks have substantially uniform width and/or are in a predictable constant sequence as the supporting belt moves through each revolution).
  • the control system 312 in the measurement zone 396, identifies a surface defect, such as a block joint impression or belt seam impression, and identifies one or more selected adjustment points (or other casting component) for possible adjustment.
  • the control system 312 selects a sensor set corresponding to one or more selected adjustment point(s) (such as adjacent and opposing adjustment point(s) on either side of a selected inter-block joint (or other casting component) entering, departing, or currently in the adjustment zone 392).
  • the sensor set for example, when the selected adjustment point(s) is/are adjustment point 328a and 328b (or other casting component) is sensor 308a in the upper set of sensors 353 and the sensor (not shown) positioned directly below sensor 308a in the lower set of sensors 355.
  • each sensor in the selected set can vary depending on the location of the surface defect relative to the sensor position.
  • a first sensor typically the upper sensor
  • the opposing second sensor typically the lower sensor
  • the thickness measuring sensor is selected as the thickness measuring sensor.
  • the second sensor typically the lower sensor
  • the opposing first sensor is selected as the thickness measuring sensor.
  • the control system 312 receives measurements from the selected sensor set and determines a thickness of the cast strip proximal to the selected sensor set.
  • the control system 312 can query the selected sensor set for a set of readings or receive multiple sets of sensor readings from all sensor sets and select the appropriate sets of readings, based on the identities of the source sensor set.
  • the selected set of sensor readings can enable the control system 312 to determine the thickness of the cast strip at the point of measurement.
  • step 608 the control system 312 compares the measured thickness to a predetermined thickness for the cast strip 130 and, in decision diamond 612, determines whether or not to adjust the selected adjustment point(s) (or other casting component). When an absolute value of a difference in the thickness from the predetermined thickness is at least a predetermined threshold, the control system 312 proceeds to step 616.
  • control system 312 can determine a difference of the measured thickness from a thickness measured by a prior set of sensor readings from the selected sensor set for an adjustment point (or other casting component) in the same plane and/or a thickness measured by one or more adjacent sensor set(s) in one or more adjacent plane(s).
  • a difference of the measured thickness from a thickness measured by a prior set of sensor readings from the selected sensor set for an adjustment point (or other casting component) in the same plane and/or a thickness measured by one or more adjacent sensor set(s) in one or more adjacent plane(s).
  • step 616 the control system 312 determines an adjustment amount and direction
  • the adjustment point(s) or other casting component
  • commands the selected adjustment point(s) (or other casting component) to be adjusted by a control signal addressed to the unique identifier of the casting component) to the determined adjustment amount and direction or recommends to a human user the adjustment amount and direction for manual adjustment of the casting component by the user (such as by the user pressing an actuator to cause movement up or down of the block in response to adjustment point activation).
  • the opposing adjustment points on either side of the inter-block joint can be adjusted in a manner to maintain the cast strip thickness at and on either side of the interblock joint 320 or other casting defect at or near the predetermined thickness.
  • the target adjustment amount may be equivalent to the difference between the measured thickness and predetermined thickness or a fraction or percentage thereof.
  • the adjustment points (or other casting component) can thus be adjusted in the same direction and by the same amount or by different amounts that sum up to the desired adjustment amount.
  • the cast strip thickness on either side of the inter-block joint can be measured and each adjustment point adjusted to produce the predetermined thickness at its respective location.
  • control system determines whether there is an adjustment point or set of adjustment points (or other casting component) in the adjustment zone. For example, when an inter-block joint is in the adjustment zone the preceding step must be repeated for each adjustment point adjacent to the inter-block joint.
  • control system returns to step 600.
  • the disclosure can apply to detection of and/or continuous casting component adjustment due to surface defects other than impressions left by block joints.
  • the disclosure can apply to any of the surface defects discussed above.
  • the disclosure can apply to automatic adjustment of components in other continuous casting techniques, such as twin-belt casters, single-roll casters, twin-roll casters, and rotary casters.
  • the casting component to be adjusted can be the back-up rolls 212 so as to maintain a substantially planar surface of the belt contacting the cast strip 130.
  • the disclosure can apply to a wide variety of alloys, such as aluminum, aluminum alloys, magnesium, magnesium alloys, copper, copper alloys, and steel.
  • Aluminum alloys for example, include AA IXXX, 2XXX, 3 XXX, 4XXX, 5 XXX, 6XXX, and 7XXX.
  • a 1000 series-based aluminum alloy typically has the following composition:
  • a 2000 series-based aluminum alloy typically has the following composition:
  • a 3000 series-based aluminum alloy typically has the following composition:
  • a 4000 series-based aluminum alloy typically has the following composition:
  • a 5000 series-based aluminum alloy useful for producing tab or end stock has the following composition:
  • a 6000 series-based aluminum alloy typically has the following composition:
  • a 7000 series-based aluminum alloy typically has the following composition:
  • the cast strip can be comprise an aluminum alloy selected from the group of consisting of aluminum alloys 1050, 1060, 1100, 1199, 2014, 2024, 2219, 303, 3004, 3102, 4041, 5005, 5052, 5083, 5086, 5154, 5182, 5356, 5454, 5456, 5754, 6005, 6005A, 6014, 6022, 6060, 6061, 6063, 6066, 6070, 6082, 6105, 6111, 6016, 6162, 6262, 6351, 6463, 7005, 7022, 7050, 7068, 7072, 7075, 7079, 7116, 7129, and 7178.
  • the cast strip can be comprise an aluminum alloy suitable for aircraft or aerospace structures selected from the group of consisting of aluminum alloys 2024, 5052, 6061, 6063, 7050, 7068, and 7075.
  • the cast strip can be comprise an aluminum alloy suitable for marine structures selected from the group of consisting of aluminum alloys 5052, 5059, 5083, 5086, 6061, and 6063.
  • the cast strip can comprise an aluminum alloy suitable for automotive structures selected from the group of consisting of aluminum alloys 2008, 2036, 5083, 5456, 5754, 6016, and 6111.
  • the bottom surface 804 shows what the surface would look like if one could look down from within the cast strip. As can be seen from the opposite side of the surface, it appears to be inverted. The high points shown are really low points when looking from underneath the sheet.
  • the before view ( Figure 8) is the sheet before the adjustment of the caster blocks.
  • Figures 7 and 8 depict irregularities or defects in the opposing upper and lower surfaces 700 and 704 ( Figure 7) and 800 and 804 ( Figure 8) of a cast strip from the block caster.
  • the cast strip 130 has multiple surface defects along its length. Some of the surface defects are higher above the adjacent surface than others.
  • defects 708 correspond to impressions of elevated inter-block joints while other lower surfaces 712 correspond to planar faces of chilling blocks.
  • the thickness "T" between the opposing surfaces is seen to vary in response to the occurrence of surface defects.
  • the after view ( Figure 7) is the sheet after the adjustment of the caster blocks.
  • the after view shows an overall smoother and more planar strip on both the upper and lower strip surfaces compared to the before view ( Figure 8).
  • the locations of the inter-block joints 708 are lower in elevation relative to the surrounding surface compared to the inter-block joints 708 of Figure 7.
  • laser radar can be used to identify impressions of block joints where slab thickness is thicker or thinner than the target stab thickness.
  • the experiment further revealed the substantial movement of the chilling blocks during casting notwithstanding the extreme care taken before casting commenced to ensure planarity of surfaces of adjacent chilling blocks. Although the blocks were adjusted to very tight tolerances, the blocks moved substantially during startup to a much greater degree than previously thought.
  • a laser measuring device properly installed to observe the cast strip can provide slab thickness consistency and enable dynamic adjustment of block height even while the caster is running or operating.
  • Some block casters have adjustment devices or adjusters located at the interface between adjacent blocks which would be used to effect computer-controlled adjustments. Additionally, block adjustments from side-to-side may also be computer-controlled. This configuration can provide block position adjustments on fore and aft sides of the block and across the width of the block at about 10 inch increments.
  • Examples of the processors as described herein may include, but are not limited to, at least one of Qualcomm® Qualcomm® Qualcomm® 800 and 801, Qualcomm® Qualcomm® Qualcomm® 610 and 615 with 4G LTE Integration and 64-bit computing, Apple® A7 processor with 64-bit architecture, Apple® M7 motion coprocessors, Samsung® Exynos® series, the Intel® CoreTM family of processors, the Intel® Xeon® family of processors, the Intel® AtomTM family of processors, the Intel Itanium® family of processors, Intel® Core® ⁇ 5-4670 ⁇ and ⁇ 7-4770 ⁇ 22nm Haswell, Intel® Core® ⁇ 5-3570 ⁇ 22nm Ivy Bridge, the AMD® FXTM family of processors, AMD® FX-4300, FX-6300, and FX-8350 32nm Vishera, AMD® Kaveri processors, Texas Instruments® Jacinto C6000TM automotive infotainment processors, Texas Instruments® OMAPTM automotive-grade mobile processors, ARM® CortexTM-
  • certain components of the system can be located remotely, at distant portions of a distributed network, such as a LAN and/or the Internet, or within a dedicated system.
  • a distributed network such as a LAN and/or the Internet
  • the components of the system can be combined in to one or more devices or collocated on a particular node of a distributed network, such as an analog and/or digital telecommunications network, a packet-switch network, or a circuit-switched network.
  • a distributed network such as an analog and/or digital telecommunications network, a packet-switch network, or a circuit-switched network.
  • the components of the system can be arranged at any location within a distributed network of components without affecting the operation of the system.
  • one or more functional portions of the system could be distributed between multiple device(s).
  • the various links connecting the elements can be wired or wireless links, or any combination thereof, or any other known or later developed element(s) that is capable of supplying and/or communicating data to and from the connected elements.
  • These wired or wireless links can also be secure links and may be capable of communicating encrypted information.
  • Transmission media used as links can be any suitable carrier for electrical signals, including coaxial cables, copper wire and fiber optics, and may take the form of acoustic or light waves, such as those generated during radio-wave and infra-red data communications.
  • control system is embodied as an artificially intelligent algorithm able to modify its behavior based on repeated
  • Artificial intelligence can observe the effects of adjusting adjustment points over time and modify to what degree and how adjustments are made to adapt to changes in behavior of the casting system. For example, blocks wear, thermal conditions change, alloy compositions change, and the like.
  • systems and methods of this disclosure can be implemented in conjunction with a special purpose computer, a programmed
  • any device(s) or means capable of implementing the methodology illustrated herein can be used to implement the various aspects of this disclosure.
  • Exemplary hardware that can be used for the disclosed embodiments, configurations and aspects includes computers, handheld devices, telephones (e.g., cellular, Internet enabled, digital, analog, hybrids, and others), and other hardware known in the art. Some of these devices include processors (e.g., a single or multiple microprocessors), memory, nonvolatile storage, input devices, and output devices.
  • alternative software e.g., a single or multiple microprocessors
  • implementations including, but not limited to, distributed processing or component/object distributed processing, parallel processing, or virtual machine processing can also be constructed to implement the methods described herein.
  • the disclosed methods may be readily implemented in conjunction with software using object or object-oriented software development environments that provide portable source code that can be used on a variety of computer or workstation platforms.
  • the disclosed system may be implemented partially or fully in hardware using standard logic circuits or VLSI design. Whether software or hardware is used to implement the systems in accordance with this disclosure is dependent on the speed and/or efficiency requirements of the system, the particular function, and the particular software or hardware systems or microprocessor or microcomputer systems being utilized.
  • the disclosed methods may be partially implemented in software that can be stored on a storage medium, executed on programmed general- purpose computer with the cooperation of a controller and memory, a special purpose computer, a microprocessor, or the like.
  • the systems and methods of this disclosure can be implemented as program embedded on personal computer such as an applet, JAVA® or CGI script, as a resource residing on a server or computer workstation, as a routine embedded in a dedicated measurement system, system component, or the like.
  • the system can also be implemented by physically incorporating the system and/or method into a software and/or hardware system.
  • present disclosure in various aspects, embodiments, and/or configurations, includes providing devices and processes in the absence of items not depicted and/or described herein or in various aspects, embodiments, and/or configurations hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and ⁇ or reducing cost of implementation.

Abstract

Un procédé comprend : la détection d'un défaut sur une surface de bande coulée, la bande coulée étant coulée à partir d'un métal ou d'un alliage fondu par un système de coulage, la détermination d'une quantité et/ou d'une direction d'ajustement d'un composant de système de coulée sur la base du défaut de surface identifié, et la fourniture de la quantité et/ou de la direction d'ajustement à un opérateur pour l'ajustement du composant du système de coulée et/ou la commande de l'ajustement du composant du système de coulée par la quantité et/ou la direction d'ajustement.
PCT/US2017/032921 2016-05-16 2017-05-16 Système et procédé d'ajustement des composants de coulée continue WO2017201059A1 (fr)

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CN111360147A (zh) * 2020-04-14 2020-07-03 太原理工大学 一种改善精密箔材表面质量的超声能场装置
CN112387947A (zh) * 2020-11-06 2021-02-23 福建三宝钢铁有限公司 一种冷镦钢的制备方法
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RU2795303C1 (ru) * 2022-08-02 2023-05-02 Общество с ограниченной ответственностью "Объединенная Компания РУСАЛ Инженерно-технологический центр" Способ автоматического непрерывного контроля качества поверхности

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WO2020061289A1 (fr) * 2018-09-20 2020-03-26 Nucor Corporation Surveillance et commande en ligne permettant l'élimination de défauts de surface survenant pendant la production d'une bande d'acier coulée
EP3722798B1 (fr) * 2019-04-09 2021-10-13 Rosen Swiss AG Procédé de détermination de la géométrie d'un point défectueux et de détermination de la capacité de charge

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RU2795303C1 (ru) * 2022-08-02 2023-05-02 Общество с ограниченной ответственностью "Объединенная Компания РУСАЛ Инженерно-технологический центр" Способ автоматического непрерывного контроля качества поверхности

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