Active temperature feedback control of continuous casting

Abstract

The invention includes a system, method and machine readable program for dynamically controlling the casting of a material. Generally, the systems and methods described herein include an active control feedback system or aspects thereof including a temperature sensing device that is well-suited for the harsh environment of the interior of a caster such as a caster for casting metal. Temperature measurement can be accomplished either directly or indirectly. The system is configured to compare the measured temperature with an ideal casting temperature. The temperature sensing device is operably coupled to a cooling device that modulates a flow of coolant to dynamically cool the material being cast. In accordance with one embodiment of the invention, the cooling device includes a plurality of nozzles for delivering one or more cooling fluids to the material being cast.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims the benefit of priority of U.S. Provisional Application Ser. No. 60 / 796,074 filed Apr. 28, 2006. This application is related to U.S. patent application Ser. No. 11 / 709,070 filed Feb. 21, 2007. Each of these applications is incorporated by reference herein in its entirety.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The present invention relates to continuous casting machines and particularly to the control of the secondary cooling in the continuous casting machines where molten metal is molded into cast slabs, strands, billets and the like.[0004]2. Description of Related Art[0005]In a continuous casting machine (or “caster”) as depicted in FIG. 1, molten metal 1 is poured into a cooled copper faced mold 2 which controls the physical width and thickness of the finished product. Metal exits the mold 2 in the form of a strand or slab having a thin shell 3 of solidified metal with a core 4 of molten ...

AI Technical Summary

Benefits of technology

[0017]In accordance with a further aspect of the invention, the program further comprises means for providing individualized control of each of a plurality of nozzles or banks of nozzles through which cooling fluid is directed inside of the caster. The program may also include means for maintaining a substantially uniform surface temperature across the surface of the stream of material while it solidifies. Moreover, the program can also include means for sensing when a molten core of the stream of material breaks out through a

Problems solved by technology

Unfortunately because of the design of modern continuous casting machines, limited control of temperature is possible.

However, no successful attempts have been made to integrate that temperature to a predetermined curve such as an ideal curve, and imprecise cooling is the result.

Breakout is a major problem.

Breakout occurs when the thin shell of the strand of material breaks, allowing the still-molten metal inside the strand to spill out and foul the casting system, requiring an expensive shutdown.

Often, breakout is due to too high a withdrawal rate, as the shell has not had the time to solidify to the required thickness, or the metal is too hot, which means that final solidification takes place below the straightening rolls and the strand breaks due to stresses applied during straightening.

Either of these failures results in costly further processing, waste, or expensive and d

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