WO2017218472A1 - Système et procédé de remplacement et d'ajustement de composants de coulée continue - Google Patents

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

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Publication number
WO2017218472A1
WO2017218472A1 PCT/US2017/037154 US2017037154W WO2017218472A1 WO 2017218472 A1 WO2017218472 A1 WO 2017218472A1 US 2017037154 W US2017037154 W US 2017037154W WO 2017218472 A1 WO2017218472 A1 WO 2017218472A1
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WO
WIPO (PCT)
Prior art keywords
casting
component
block
casting component
chilling
Prior art date
Application number
PCT/US2017/037154
Other languages
English (en)
Inventor
Chris Michael MOELLERS
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 WO2017218472A1 publication Critical patent/WO2017218472A1/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
    • B22D11/14—Plants for continuous casting
    • B22D11/143—Plants for continuous casting for horizontal casting
    • 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
    • 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
    • B22D11/004—Copper alloys
    • 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
    • B22D11/18—Controlling or regulating processes or operations for pouring
    • 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
    • B22D11/18—Controlling or regulating processes or operations for pouring
    • B22D11/181—Controlling or regulating processes or operations for pouring responsive to molten metal level or slag level
    • B22D11/185—Controlling or regulating processes or operations for pouring responsive to molten metal level or slag level by using optical means
    • 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
    • B22D11/18—Controlling or regulating processes or operations for pouring
    • B22D11/181—Controlling or regulating processes or operations for pouring responsive to molten metal level or slag level
    • B22D11/186—Controlling or regulating processes or operations for pouring responsive to molten metal level or slag level by using electric, magnetic, sonic or ultrasonic means

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 (or nearly 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.
  • a depression on the back side of a belt caster can pulse the entire belt, much like an Indian smoke signal blanket.
  • Belt casters can have a depression from grinding the weld joint below flush.
  • a surface defect can also result from a bad caster stop event.
  • continuous casting systems include without limitation single-roll casters, twin-roll casters, and rotary casters.
  • components such as blocks and back-up rolls
  • Component repair or replacement often require the caster to be shut down, with concomitant loss of cast strip production.
  • the economic cost of lost cast strip production can be substantial depending on caster down time.
  • a casting system can include:
  • a casting assembly to cool and mold the molten metal or metal alloy to form a cast strip
  • a casting component changer to replace a first casting component by a second casting component
  • a microprocessor executable control system operable to determine an adjustment amount and/or direction of the second casting system component and provide the adjustment amount and/or direction to an operator for adjustment of the second casting system component and/or command that the second casting system component be adjusted by the adjustment amount and/or direction.
  • the sensors can be one or more of a laser radar detector, a mechanical
  • displacement device an imaging device, an optical 3d measuring system, and an ultrasound transducer.
  • the replacing, sensing, determining, providing, and/or commanding operations can occur while the casting system is casting a metal or metal alloy.
  • the molten metal or metal alloy is commonly one or more of manganese, a manganese alloy, aluminum, an aluminum alloy, copper, a copper alloy, iron, and an iron alloy.
  • the microprocessor executable control system can select the second casting component from among multiple possible casting components to replace the first casting component.
  • the replacing operation can include disengaging the first casting component from the guide track, removing the first casting component from a first position on the guide track, positioning the second casting component at the first position on the guide track, and engaging the second casting component with the guide track.
  • the replacing operation can include locating the second casting component adjacent to the first casting component, maintaining the second casting component adjacent to the first casting component as the first casting component moves in response to operation of the casting system, displacing, by contact with the second casting component, the first casting component from a first position on the guide track, and locating the second casting component in the first guide track position.
  • the casting system can further 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 component can alternatively be one or more of a roller, belt, back-up roll, and block belt.
  • the microprocessor executable 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 casting system component requiring replacement and enable automatic or semi-automatic component replacement and adjustment of the replacement casting system component, during casting system operation, to inhibit, remove, or reduce the formation of surface defects in a next casting cycle (e.g., next revolution of a roll, block or belt caster). This can eliminate the need not only for manual block adjustment but also for shutting down the casting system to replace a casting system component and reset an improperly adjusted replacement casting system component. 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”.
  • 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 partial side view of a block casting system according to an
  • Figure 7 is a partial top view of a block casting system according to an
  • Figure 8 is a side view of a block carrying system according to an embodiment of this disclosure.
  • Figure 9 is a side view of a block according to an embodiment of this disclosure.
  • Figure 10 is a flow chart of control logic according to an embodiment.
  • Figure 1 1 is a side view of a modified block caster according to an embodiment.
  • FIGS 3, 4, and 6 depict an embodiment of a block casting system 300 according to this disclosure.
  • the block casting system has upper and lower sets 304 of chilling blocks 316, each engaged with a corresponding endless or continuous track guide 608, to cool and solidify the molten metal into a cast strip 130, plural sensors 308 located above and below, respectively, each set of upper and low chilling block sets 304 to detect chilling block surface irregularities (e.g., steps, offsets, and other interruptions in the surface planes of adjacent chilling blocks which typically occur at inter-block joints 320 as shown in Figure 4 (the solid line refers to the joint 320 between adjacent chilling blocks 316 in the upper set 304a of chilling blocks and dashed lines refer to the joints 320 between adjacent chilling blocks in the lower set 304b of chilling blocks)) and belt seams, and 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 increase adjacent
  • 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 replacing and/or 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.
  • Figures 3 and 4 depict the control system with respect to the upper set of chilling blocks, it is to be understood that a similar system is used to monitor and adjust the lower set of chilling blocks.
  • each chilling block 316 in the upper and lower sets 304 of chilling blocks, which are positioned on one of the opposing sides of the cast strip 130, includes multiple adjustment points or adjustment devices 328
  • adjustment points typically located at or near each joint 320.
  • the 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 to be 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 304 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 in the cast strip-contacting surfaces of the upper and lower chilling block sets 304. Examples include a laser radar detector (which uses a laser beam 350 to determine the distance from the sensor to the block surface), mechanical displacement device (which measures the vertical variations in travel or movement of a wheel or other contact device with the block surface), imaging device (which uses image processing to identify surface irregularities and other variations in block surface topology, such as image processing based on the block 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 block 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 chilling block surface).
  • a laser radar detector which uses a laser beam 350 to determine the distance from the sensor to the block surface
  • mechanical displacement device which measures the vertical variations in travel or
  • Laser radar for example, can operate on the time of flight principle by sending a laser pulse in a narrow beam towards the chilling block surface to be measured and measuring the time taken by the pulse to reflect off the target chilling block surface and return 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 of electromagnetic energy by the target chilling block surface and then solves various simultaneous equations to yield a final distance measure from the sensor to the target chilling block 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 target chilling block surface is translated into a frequency offset) and interferometry (which measures changes in distance between the sensor and the target chilling block 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 in the upper or lower set of chilling blocks (e.g., above or below the cast slab 130)) and a second identifier indicating which sensor of the
  • the geometry of the block casting system 300 can be important. Referring to
  • the centers of the adjustment points and centers of the corresponding sensor can be located in or along a common plane.
  • the centers of the top row of adjustment points 328 and respective sensor 308 can lie in plane 360
  • the centers of the next row of adjustment points 328 and respective sensor 308 can lie in plane 36
  • the centers of the next row of adjustment points 328 and respective sensor 308 can lie in plane 368
  • the centers of the next row of adjustment points 328 and respective sensor 308 can lie in plane 372
  • the centers of the next row of adjustment points 328 and respective sensor 308 can lie in plane 376
  • the centers of the next row of adjustment points 328 and respective sensor 308 can lie in plane 378.
  • the centers of the upper and lower sets of sensors 308 (the upper set of sensors 308 corresponding to the upper set of chilling blocks and the lower set of sensors 308 corresponding to the lower set of chilling blocks) can lie in a common plane 382.
  • Each of the upper and lower sets of chilling blocks has separate adjustment and measurement zones 392 and 396 controlled by separate or a common adjustment control system 312.
  • the distance 388 between the adjustment 392 and measurement zones 396 for each of the upper and lower sets of chilling blocks is selected such that the chilling block currently in the upper or lower adjustment zone 392 corresponds to a set of distance measurements previously taken in the corresponding upper or lower measurement zone 396 by the respective sensor 308.
  • each adjustment zone 392 is located before the cooler 126.
  • each adjustment zone 392 is located after the cooler 126.
  • each adjustment zone 396 is located before and/or after the cooler 126 (which location can be differently selected for the upper versus the lower chilling block sets).
  • the measurement zone 396 is commonly located before the cooler 126 but can alternatively or additionally be located after the cooler 126.
  • Figure 6 depicts a casting system configuration in which the measurement zone 308 is located before the cooler 126 and the corresponding adjustment zone 392 is located after the cooler 126.
  • 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. If the adjustment zone were located entirely after the cooler, the cooler would be modified to accept excessively non-flush conditions. If part of the adjustments, or the rough adjustments, were performed before the cooler and the final finer adjustments made after the cooler, cooler performance would not be substantially impacted adversely and the cooler would not need to be redesigned.
  • 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 inter-block joint surface irregularities in adjacent chilling blocks commonly alternate between the upper and lower cast strip surfaces as the cast strip moves through the measurement and adjustment zones 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.
  • Each of the upper and lower sets of chilling blocks has a corresponding block changer 604 ( Figure 6) to slide, rotate, lift, or translate an old chilling block out of position on the track guide 608 and slide, rotate, lift, or translate, as appropriate, a new chilling block into old block's position on the track guide.
  • the block changer 604 can be any device suitable for these operations, such as a robotic arm, a boom, and a push or pull (e.g., telescopic) arm or piston.
  • Mechanical displacement mechanisms for a push or pull arm of piston include, without limitation, a ratchet mechanism (e.g., pawl and ratchet), a gear, cogwheel or sprocket mechanism (e.g., two or more meshing gears, such as spur gear(s), helical gear(s), double helical gear(s), bevel gear(s), spiral bevel gear(s), hypoid gear(s), crown gear(s), worm gear(s), non-circular gear(s), rack and pinion gear(s), epicyclic gear(s), sun and planet gear(s), harmonic gear(s), cage gear(s), and magnetic gear(s)).
  • Other displacement mechanisms include, without limitation, hydraulic, electromechanical, and electromagnetic mechanisms.
  • FIGS 7-9 depict an embodiment of a block changing system 700.
  • the block changing system 700 includes a block changer 604, set of new blocks 704, and set of old (or previously replaced) blocks 708.
  • the sets of new and old blocks are positioned on either side of the set of upper or lower chilling blocks 304, which are in operation producing cast strip 130. Alternatively, the sets of new and old blocks can be positioned on a common side of the set of upper or lower chilling blocks 304.
  • the block is disengaged from the track guide 608, a new block 316 pushed by the block changer 604 from the set of new blocks 704 against the selected one of the set of upper or lower chilling blocks, thereby displacing it from its disengaged operating position on the track guide and moving it to the set of old blocks.
  • the new block is in the disengaged operating position on the track guide, it is engaged with the track guide to place or lock it in operating position for casting the cast strip 130.
  • the selected one of the upper or lower chilling blocks 708 can be guided out of the disengaged operating position by an integral rail or track or other guidance system.
  • the selected one of the set of upper or lower chilling blocks 708 is shown as being displaced out of position by contact with the new block 316, the selected one of the upper or lower chilling blocks 708 can be moved out of the operating position and the new block moved into the same operating position with no inter-block contact.
  • a cartridge system can be employed.
  • the replaced block can be slid out of disengaged operating position into an empty receiving cartridge (not shown).
  • the now occupied receiving cartridge is then moved away from the upper or lower set of chilling blocks and a new empty receiving cartridge moved into alignment with the next selected one of the set of upper or lower chilling blocks 708 to be replaced.
  • the new block can be moved out of a receiving cartridge (not shown) and into the disengaged operating position followed by movement of the now empty receiving cartridge away from the upper or lower set of chilling blocks.
  • Receiving cartridges assist in positioning and aligning the new blocks with the selected one of the set of upper or lower chilling blocks 708 to be replaced and removing the replaced block.
  • the next cartridge containing a new block is moved into alignment with the next selected one of the set of upper or lower chilling blocks 708 to be replaced and the process repeated.
  • the cartridges are on a common carrier positioned on a common side of the set of upper or lower chilling blocks. With both old and new blocks on the common side, the block changer moves new blocks and empties cartridges and moves replaced blocks into the now emptied cartridges.
  • the two block cartridges i.e., empty cartridge to receive the replaced block and cartridge containing the new block
  • An example of this type of system is shown in Figure 8.
  • Old or new blocks 316 are positioned on a carrier structure 800 having one or more rotatable supports 804 to enable the carrier structure 800 to move back and forth in response to movement of a translation mechanism 808.
  • the translation can be hydraulic, mechanical, electrical, electromagnetic, or electromechanical.
  • a hydraulic pump 812 moves a telescopic hydraulic cylinder 816 engaged with a connector 820 on the carrier structure forward in response to movement with the selected one of the set of upper or lower chilling blocks and backward after block replacement to position to replace a next block.
  • a hydraulic pump 812 moves a telescopic hydraulic cylinder 816 engaged with a connector 820 on the carrier structure forward in response to movement with the selected one of the set of upper or lower chilling blocks and backward after block replacement to position to replace a next block.
  • other carrier structures can be employed depending on the application.
  • one or more robotic arms is/are employed.
  • a first robotic arm engages the selected one of the set of upper and lower chilling blocks to be replaced and follows the selected block as the caster is moving.
  • a second robotic arm pulls a new block from a rack, the selected block is disengaged from the track guide, the first robotic arm moves the selected block from the disengaged operating position to a rack, while the second robotic arm places the new block into the disengaged operating position. Then, the new block is engaged with the track guide.
  • one or more adjustment points 328 of a chilling block include an inward or outward facing pin 900 that releasably engages a hole or slot in a connector (not shown) on the track guide.
  • the pin engages the connector when the block is in the engaged operating position and does not engage the connector when the block is in the disengaged operating position.
  • the track guide can include one or more channels (not shown) along which the downwardly protruding ends 904 of the adjustment points 328 are guided in response to movement of the chilling block.
  • FIG. 11 shows a circular block caster 1100 that is a combination of a roll caster and block caster.
  • each of the upper and lower sets of chilling blocks 1104a and b includes a plurality of chilling blocks 1108 engaging a central mandrel 1112.
  • each chilling block is arcuately shaped.
  • Each of the upper and lower sets of chilling blocks are cooled by a cooler 1116.
  • Each of the chilling blocks 1108 can be independently and selectively replaced and adjusted in any manner, including by the techniques disclosed above.
  • the adjustment control system 312 selects a chilling block in one of the sets of upper and lower chilling blocks to be replaced.
  • the selection can be based on user input and/or parameters sensed by one or more sensors. For example, consistently sensing a surface defect in a portion of a cast strip contacted by a given block indicates that the block is damaged or worn and requires replacement. The sensing can be based on a vision or dimension defect on the cast strip.
  • the responsible chilling block in the set of upper and lower set of chilling blocks casting the defect-containing upper or lower cast strip surface
  • the responsible chilling block is identified, such as by determining a rate of advance of the cast strip and/or rate of rotation of the chilling blocks and, based on the distance traversed by the cast strip during the time interval since the defect was first or last contacted with a chilling block and ending when the defect was sensed, determining the chilling block located at that distance along the face of the block caster.
  • the defect can be sensed by any of the sensors identified above.
  • the sensors can be the same as or in addition to the sensors providing feedback to control chilling block adjustment.
  • the adjustment control system 312 determines the selected chilling block's dimensions. This can be done by any technique, including user input or a look up table mapping the identity of the selected block against one or more dimensions (e.g., length, width, and/or thickness) of the block.
  • a robotic arm can measure one or more dimensions of the selected block.
  • a non-contact device can remain stationary and timely measure the dimensions.
  • the adjustment control system 312 selects a new or replacement chilling block having one or more similar dimension(s). This can be done by any technique, including user input or a look up table mapping the positions of the replacement blocks against one or more dimensions (e.g., length, width, and/or height) of the block.
  • a robotic arm can measure one or more selected dimensions of each of the replacement blocks and select that replacement block having the closest selected dimension(s).
  • the adjustment control system 312 aligns the selected replacement block with the selected block to be replaced and replaces the selected block.
  • a look up table can be updated to reflect one or more dimension(s) of the replacement block for the block dimensions of the corresponding block operating position in the set of upper or lower chilling blocks.
  • the adjustment control system 312 can, based on the difference between the thicknesses of the replaced block and the replacement block, effect rough adjustments to form a substantially planar surface with adjacent chilling blocks.
  • the system should be able to handle the entire range of block dimensions. It is possible, however, to design a block casting system in which all of the blocks are relatively close in dimension (particularly when the expansion and contraction of thermal heating and cooling events occurs).
  • the adjustment control system 312 selects a sensor corresponding to a selected adjustment point in the measurement zone.
  • the control system can identify a set of adjustment points for the replacement chilling block and/or inter-block joint entering the adjustment zone in many ways.
  • a position of a selected chilling block and/or inter-block joint 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 track guides in the case of a belt caster). Based on this monitored location, the locations of the other chilling block and/or inter-block joints are readily determined (as the chilling blocks have known widths and/or are in a predictable constant sequence as the supporting track guide moves through each revolution).
  • 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.
  • the control system 312 receives measurements from the selected sensor and determines a distance to the replacement block surface.
  • the control system 312 can query the selected sensor for a set of readings or receive multiple sets of sensor readings from all sensors and select the appropriate set of readings, based on the identities of the source sensor.
  • the selected set of sensor readings can enable the control system 312 to determine the distance at the point of measurement.
  • the control system 312 compares the measured distance to a predetermined or reference distance and/or a distance measured to a portion of the block surface of an adjacent block and, in decision diamond 1028, determines whether or not to adjust the selected adjustment point(s).
  • control system 312 determines a difference of the measured distance from a distance measured by a prior set of sensor readings from the selected sensor for an adjustment point (or a portion of the block surface of an adjacent block) in the same plane and/or a distance measured by one or more adjacent sensor(s) in one or more adjacent plane(s).
  • the control system 312 proceeds to step 1032.
  • the control system 312 determines an adjustment amount and direction (e.g., up or down and either commands the selected adjustment point(s) to be adjusted (by a control signal addressed to the unique identifier of the adjustment point) to the determined adjustment amount and direction or recommends to a human user the adjustment amount and direction for manual adjustment of the adjustment point 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).
  • an adjustment amount and direction e.g., up or down and either commands the selected adjustment point(s) to be adjusted (by a control signal addressed to the unique identifier of the adjustment point) to the determined adjustment amount and direction or recommends to a human user the adjustment amount and direction for manual adjustment of the adjustment point 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).
  • an adjustment amount and direction e.g., up or down and either commands the selected adjustment point(s) to be adjusted (by a control signal addressed to the unique identifier of
  • the target adjustment amount may be equivalent to the difference between the measured distance on either side of the inter-block joint 320 or a fraction or percentage thereof.
  • the adjustment points 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 distance on either side of the inter-block joint can be measured and each adjustment point on either side of the joint adjusted to produce a substantially identical distance at its respective location.
  • step 1032 the control system, in decision diamond 1036 determines whether there is an adjustment point or set of adjustment points 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. When a further adjustment point(s) for the inter-block joint remains to be considered for adjustment, the control system returns to step 1016.
  • control system returns to step 1000.
  • the disclosure can apply to detection of and/or continuous casting component replacement and adjustment and inhibit 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 replacement and 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 replaced and 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 back-up roll can be replaced by a robotic arm or other suitable automated technique followed by adjustment of the replacement back-up roll, which commonly has dimensional adjustments at the bearings.
  • the same can be true of a roll caster, with eccentricities, flat spots, and coating thickness variations.
  • the roll can be replaced by a robotic arm or other suitable automated technique followed by adjustment of the replacement roll, which commonly has a point of adjustment or adjustment point at the bearing points.
  • 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.
  • 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 1XXX, 2XXX, 3 XXX, 4XXX, 5 XXX, 6XXX, and 7XXX.
  • a 1000 series-based aluminum alloy typically has the following composition: (i) from about 0.05 to about 0.20 % by weight magnesium; (ii) from about 0.01 to about 0.20 % by weight manganese;
  • 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:
  • 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 casting component wear on casting performance and cast strip surface properties/defects and adjusting adjustment points over time and modify when the component is replaced and 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
  • 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.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)

Abstract

Un procédé comprend les étapes consistant à : remplacer un premier composant d'un système de coulée par un deuxième composant du système de coulée ; détecter une position du deuxième composant du système de coulée par rapport à une position de référence et/ou à un troisième composant du système de coulée ; déterminer une quantité d'ajustement et/ou une direction du deuxième composant du système de coulée ; puis communiquer la quantité d'ajustement et/ou la direction à un opérateur en vue d'un ajustement du deuxième composant du système de coulée et/ou transmettre une instruction telle que le deuxième composant du système de coulée est ajusté selon la quantité d'ajustement et/ou la direction.
PCT/US2017/037154 2016-06-13 2017-06-13 Système et procédé de remplacement et d'ajustement de composants de coulée continue WO2017218472A1 (fr)

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4014641A1 (de) * 1990-05-08 1991-11-14 Bayerische Motoren Werke Ag Niederdruck-giessanlage
US5697423A (en) * 1994-03-30 1997-12-16 Lauener Engineering, Ltd. Apparatus for continuously casting
US20060191664A1 (en) * 2005-02-25 2006-08-31 John Sulzer Method of and molten metal feeder for continuous casting
US7191819B2 (en) * 2004-12-07 2007-03-20 Nucor Corporation Continuously casting steel strip
US7556084B2 (en) * 2006-03-24 2009-07-07 Nucor Corporation Long wear side dams
US7905272B2 (en) * 2006-12-14 2011-03-15 Mkm Mansfelder Kupfer Und Messing Gmbh Method and device for the production of wide strips of copper or copper alloys
US8307541B2 (en) * 2008-12-23 2012-11-13 Optimize Technologies, Inc. Assembly for placing an insert into communication with an analytical chemical instrument
US8631853B2 (en) * 2008-03-19 2014-01-21 Nucor Corporation Strip casting apparatus for rapid set and change of casting rolls

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4014641A1 (de) * 1990-05-08 1991-11-14 Bayerische Motoren Werke Ag Niederdruck-giessanlage
US5697423A (en) * 1994-03-30 1997-12-16 Lauener Engineering, Ltd. Apparatus for continuously casting
US7191819B2 (en) * 2004-12-07 2007-03-20 Nucor Corporation Continuously casting steel strip
US20060191664A1 (en) * 2005-02-25 2006-08-31 John Sulzer Method of and molten metal feeder for continuous casting
US7556084B2 (en) * 2006-03-24 2009-07-07 Nucor Corporation Long wear side dams
US7905272B2 (en) * 2006-12-14 2011-03-15 Mkm Mansfelder Kupfer Und Messing Gmbh Method and device for the production of wide strips of copper or copper alloys
US8631853B2 (en) * 2008-03-19 2014-01-21 Nucor Corporation Strip casting apparatus for rapid set and change of casting rolls
US8307541B2 (en) * 2008-12-23 2012-11-13 Optimize Technologies, Inc. Assembly for placing an insert into communication with an analytical chemical instrument

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