Automatic dam positioning systems and methods for controlling molten metal distribution to continuous casters

Abstract

A metal feeding system includes an injector for distributing a molten metal into a movable mold, a supply container upstream from the injector and defining a receiving area for receiving the molten metal, and a dam system. The dam system includes a dam positionable within the receiving area and a controller that may vertically position the at least one dam for controlling a flow of molten metal from the receiving area to the injector. A method of controlling a molten metal distribution to a continuous casting device includes at least partially blocking a flow of a molten metal from a receiving area to an injector using at least one dam in the receiving area. The method may include detecting a temperature of the molten metal downstream from the at least one dam and controlling a vertical position of the at least one dam based on the detected temperature.

Description

REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 362,135, filed on March 30, 2022, and entitled AUTOMATIC DAM POSITIONING SYSTEMS AND METHODS FOR CONTROLLING MOLTEN METAL DISTRIBUTION TO CONTINUOUS CASTERS.FIELD OF THE INVENTION

[0002] This application relates to continuous casting of molten metal, and more specifically to systems and methods for controlling the flow of molten metal to a movable mold for casting, the movable mold including but not limited to blocks, belts, and / or rolls.BACKGROUND

[0003] Metal products (such as metal strip, slab and plate), particularly those made of aluminum and aluminum alloys, can be produced using a continuous casting system in which molten metal is introduced into a gap formed by a movable mold. A metal product is continuously ejected from the casting cavity by the movable mold and may be produced in indefinite length. Various types of movable molds may be used depending on the type of continuous casting system. For example, one form of a continuous casting system is a twin-belt caster in which two confronting belts are circulated continuously and molten metal is introduced by means of a launder or injector into a thin casting cavity formed between the confronting regions of the belts. An alternative is a rotating block caster in which the casting surfaces are formed by blocks that rotate around a fixed path and join together adjacent the casting cavity to form a continuous surface. Yet another type of continuous casting system is a twin roll caster in which the metal is cast by supplying molten metal, using an injection device, into a gap formed between two rolls. As the metal comes in contact with the rolls, heat is rapidly extracted and the metal begins to solidify. The solidified metal is then compressed as it passes through the gap between the rolls.

[0004] In some continouous casting systems such as twin roll casters, an exit cross-sectional profile of a cast metal product is directly related with a temperature profile of molten metal at a tip of an injector introducing the molten metal into the gap of the movable mold. However, control of such a temperature profile has traditionally been limited and required an operator to manually implement controls in close proximity to the molten metal, which increases the likelihood of occupational incidents. Moreover, traditional controls have been imprecise, unable to quickly address issues, and subject to variations, thereby leading to cast metal products that are of an undesirable shape and / or need to be corrected before further processing which decreases productivity.

[0005] For example, EP 0 596 202 A1 discloses a metal feeding system comprising an injector for distributing a molten metal into a movable mold, a supply container upstream from the injector and defining a receiving area configured to receive the molten metal, and a dam system comprising at least one dam positionable within the receiving area, and a controller operably coupled to the at least one dam, the controller configured to vertically position the at least one dam within the receiving area for controlling a flow of molten metal from the receiving area to the injector. EP 0 761 343 A1 and FR 2 775 916 A1 disclose similar systems.SUMMARY

[0006] Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter.

[0007] According to the invention, a metal feeding system includes an injector for distributing a molten metal into a movable mold, a supply container upstream from the injector and defining a receiving area for receiving the molten metal, and a dam system. The dam system includes at least one dam positionable within the receiving area and a controller operably coupled to the at least one dam for controlling a vertical position of the at least one dam within the receiving area to control a flow of molten metal from the receiving area to the injector.

[0008] According to the invention, a dam system for a metal feeding system includes a plurality of dams and a controller operably coupled to each dam of the plurality of dams. The controller may control a vertical position of each dam of the plurality of dams independently from the other dams of the plurality of dams.

[0009] According to the invention, a method of controlling a molten metal distribution to a continuous casting device includes at least partially blocking a flow of a molten metal from a receiving area to an injector using at least one dam in the receiving area, detecting a temperature of the molten metal downstream from the at least one dam, and controlling a vertical position of the at least one dam based on the detected temperature.

[0010] Various implementations described herein may include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components. FIG. 1 is a side view of a twin roll casting system with a metal feeding system according to embodiments. FIG. 2 is a top view of a portion of the metal feeding system of FIG. 1. FIG. 3 illustrates a portion of a dam system of the metal feeding system of FIG. 1. FIG. 4 illustrates a portion of a twin roll casting system with a metal feeding system according to embodiments. FIG. 5 illustrates a portion of a dam system of the metal feeding system of FIG. 4. FIG. 6 illustrates a portion of the dam system of the metal feeding system of FIG. 4. FIG. 7 illustrates an actuator of the dam system of the metal feeding system of FIG. 4. DETAILED DESCRIPTION

[0012] Described herein are systems and methods for controlling a distribution of molten metal to a continuous casting device including but not limited to a twin roll caster. While the systems and methods described herein can be used with any metal, they may be especially useful with aluminum or aluminum alloys. In an unclaimed aspect, a metal feeding system for supplying molten metal to the continuous casting device includes a dam system with at least one movable dam and a controller. According to the invention, the dam system includes a plurality of movable dams, such as but not limited to two movable dams, three movable dams, four movable dams, five movable dams, six movable dams, seven movable dams, eight movable dams, nine movable dams, etc. In some embodiments, the dam system includes an odd number of movable dams, although it need not in other embodiments.

[0013] The controller is operably coupled to the dams to control a vertical position of the dams within a flow path of the molten metal (e.g., within a receiving area of a supply container or tundish), thereby controlling the distribution of molten metal to the continuous casting device and providing improved profile control of the cast metal product. In various embodiments, the controller is mechanically coupled to the dams for improved durability and reliability of the connection and control of the at least one dam in difficult working conditions (e.g., in close proximity to molten metal and in close proximity to a continuous casting device). According to the invention, the dam system includes a sensor associated with each dam, and the sensor may detect a temperature of the molten metal downstream from the dam. The controller controls a vertical position of the dams based on the detected temperature to provide a desired temperature distribution of the molten metal entering the continuous casting device, which in turn improves profile control of the cast metal product. According to the invention, the dam system includes a plurality of dams, and each dam may be independently controlled by the controller for improved control of the metal distribution and / or temperature distribution of the molten metal supplied to the continuous casting device. Various other benefits and advantages may be realized with the systems and methods provided herein, and the aforementioned advantages should not be considered limiting.

[0014] FIGS. 1-3 illustrate a continuous casting system 100 with a continuous casting device 102 and metal feeding system 104 according to embodiments.

[0015] In the example of FIGS. 1-3, the continuous casting device 102 is a twin roll caster 106 with a pair of rolls 108A-B as the movable mold. Each roll 108A-B rotates about an axis as represented by the arrows 110A-B. A gap 112 is defined between the rolls 108A-B, and during casting, molten metal is supplied by the metal feeding system 104 into the gap 112. As the metal comes in contact with the rolls 108A-B, heat is rapidly extracted and the metal begins to solidify. The solidifying metal is further compressed as it passes through the gap 112 between the rolls 108A-B and exits the continuous casting device 102 (represented by arrow 144) as a cast metal product 114 (e.g., a sheet, a plate, a shate, etc.). While the continuous casting device 102 is illustrated as the twin roll caster 106, in other embodiments, the continuous casting device 102 may be various other types of continuous casting devices as desired, including but not limited to belt casters, block casters, and / or other casting devices as desired.

[0016] The metal feeding system 104 generally includes an injector 116, a supply container 118, and a dam system 120. The injector 116 includes an tip 122, and molten metal may be introduced into the gap 112 of the casting device 102 through the tip 122. In the embodiment illustrated in FIGS. 1 and 2, the injector 116 includes a bottom wall 124 and a top wall 126 that converge towards the tip 122, as well as side walls 128. However, the particular shape and profile of the injector 116 should not be considered limiting, and the injector 116 may have various shapes and profiles as desired suitable for supplying the molten metal to the casting device 102. As some non-limiting examples, the side walls 128 may be converging, parallel, or diverging, and the walls 124, 126 may be converging or parallel. The injector 116 may have additional walls and / or shapes as desired.

[0017] The supply container 118 (e.g., a tundish) is upstream from the injector 116 and generally defines a receiving area 130 (see FIGS. 2 and 3) for initially receiving the molten metal. In the embodiment illustrated and as best shown in FIG. 2, the supply container 118 includes an introduction portion 132, which may initially receive the molten metal, and a main portion 134 between the introduction portion 132 and the injector 116. However, the shape and profile of the supply container 118 should not be considered limiting, and the supply container 118 and / or the receiving area 130 may have various shapes, sizes, and profiles as desired.

[0018] The dam system 120 includes at least one dam 136 and a controller 138 operably coupled to the at least one dam 136. In an unclaimed aspect, the dam system 120 includes a single dam, but according to the invention, the dam system 120 includes a plurality of dams. In the embodiment of FIGS. 1 and 2, the dam system 120 includes five dams 136A-E. In embodiments with a plurality of dams 136, each dam 136 optionally may be operably coupled to the controller 138. As best illustrated in FIG. 2, the dams 136 of the dam system 120 may be provided along a width of the receiving area 130 of the supply container 118 (e.g., in a direction transverse to a direction of flow of the molten metal). In certain embodiments, the dams 136 need not be provided along the entire width of the receiving area 130. In some non-limiting examples, the dams 136 are provided along at least 30% of the width of the receiving area 130, such as at least 40% of the width of the receiving area 130, such as at least 50% the width of the receiving area. However, in other embodiments, the dams 136 may be provided along any extent of the width of the receiving area 130 as desired. As discussed in detail below, the dam(s) 136 are vertically positionable within the receiving area 130 (represented by arrow 141 in FIG. 1) for controlling the flow of molten metal to the injector 116. FIG. 3 illustrates a non-limiting example of the dams 136A-E at various vertical positions within the receiving area 130.

[0019] The controller 138 is operably coupled to the dams 136 to control a vertical position of the dams 136 within the receiving area 130. According to the invention, the controller 138 controls the vertical position of each dam 136 independent from the other dams 136. In other embodiments, the controller 138 may jointly control the vertical position of two or more dams 136 as desired. Control of the vertical positions of the dams 136 may control the distribution of molten metal to the injector 116 and thus to the casting device 102, which in turn may control the profile of the cast metal product 114. In certain embodiments and as discussed below, controlling the vertical positions of the dams 136 may control a temperature distribution in the molten metal provided to the injector 116, which may control the profile of the cast metal product 114. As illustrated in FIG. 3, when the dam system 120 includes a plurality of dams 136, the controller 138 may control the dams 136 to be at various vertical positions as desired, and the vertical position of one dam 136 need not be the same as another dam 136.

[0020] The controller 138 may include one or more processing units and / or one or more memory devices. The processing unit of the controller may be various suitable processing devices or combinations of devices including but not limited to one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), programmable logic controller (PLC), field programmable gate arrays (FPGAs), processors, controllers, micro-controllers, microprocessors, other electronic units, and / or a combination thereof. The one or more memory devices of the controller 138 may be any machine-readable medium that can be accessed by the processor, including but not limited to any type of long term, short term, volatile, nonvolatile, or other storage medium, and is not to be limited to any particular type of memory or number of memories, or type of media upon which memory is stored. Moreover, as disclosed herein, the term "storage medium", "storage" or "memory" can represent one or more memories for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage mediums, optical storage mediums, flash memory devices and / or other machine readable mediums for storing information. The term "machine-readable medium" includes, but is not limited to, portable or fixed storage devices, optical storage devices, wireless channels, and / or various other storage mediums capable of storing that contain or carry instruction(s) and / or data. The aforementioned examples of processing devices and memory devices should not be considered limiting, and the controller 138 may include various types of processing devices and / or memory devices as desired.

[0021] In certain embodiments, the controller 138 optionally includes an associated user interface, including but not limited to a graphical user interface, such that the controller 138 may obtain information from a user and / or provide information to the user. In such embodiments, the user interface may be on the controller 138 itself or may be at a location remote from the controller 138 such as, but not limited to, another location within the casting system 100. Additionally or alternatively, the controller 138 optionally may include various communication modules such that the controller 138 may receive and / or send information as desired. Non-limiting examples of communication modules may include systems and mechanisms enabling wired communication and / or wireless communication (e.g., near field, cellular, Wi-Fi, Bluetooth ®< , Bluetooth Low Energy (BLE), etc.).

[0022] In certain embodiments, the controller 138 includes at least one actuator 140 for mechanically and operably coupling the controller 138 to the dam(s) 136 of the dam system 120. Actual mechanical coupling between the actuator 140 and the dams 136 in FIG. 1 has been omitted for clarity of the figure. Each dam 136 optionally may include a dedicated actuator 140 which may facilitate independent control of the dams 136. In certain embodiments, the mechanical coupling provided by the actuator 140 may provide improved durability and reliability of the connection between the controller 138 and the dam 136 for controlling the vertical position of the dam 136 in difficult working conditions (e.g., in close proximity to molten metal and in close proximity to the continuous casting device 102). The at least one actuator 140 may be various devices, mechanisms, or systems as desired. In one non-limiting embodiment, the actuator 140 includes a motor with a plurality of flexible shafts that are driven by the motor.

[0023] Referring back to FIG. 1, in an unclaimed embodiment, in addition to the dam(s) 136 and the controller 138, the dam system 120 includes at least one temperature sensor 142 associated with the at least one dam 136. The at least one temperature sensor may be various suitable devices or mechanisms suitable for detecting a temperature of the molten metal downstream from the at least one dam 136. In some embodiments, the at least one temperature sensor 142 is provided upstream from the tip 122 of the injector 116, although the particular location of the sensor 142 should not be considered limiting.

[0024] In an unclaimed embodiment, the at least one temperature sensor 142 is communicatively coupled with the controller 138, and the controller 138 may control the vertical position of the at least one dam 136 based on the detected temperature from the corresponding temperature sensor 142. According to the invention, with a plurality of dams 136, the dam system 120 includes a plurality of temperature sensors 142, and each temperature sensor 142 is associated with a particular dam 136. As an example and as illustrated in FIG. 2, the dam system 120 may include five temperature sensors 142A-E, each of which is associated with a corresponding dam 136A-E. In this embodiment, the controller 138 may control the vertical position of each dam 136A-E based on the temperature detected by each associated temperature sensor 142A-E. As a non-limiting example, the controller 138 may raise dam 136C to increase a metal flow and temperature of the molten metal downstream from the dam 136C based on the temperature detected by the temperature sensor 142C being less than a predetermined value. Such independent control of the dams 136A-E based on the corresponding temperature sensors 142A-E may enable the controller 138 to distribute molten metal with a desired flow and / or temperature distribution for a desired profile of a cast metal product.

[0025] Optionally, the dam system 120 includes at least one system sensor 146 for detecting a parameter of the continuous casting system 100. The at least one system sensor 146 may be communicatively coupled with the controller 138, and the controller 138 optionally may control one or more of the dams 136 based on information detected by the at least one system sensor 146. The number, type, location, and parameter detected by the at least one system sensor 146 should not be considered limiting. In the embodiment illustrated, a single system sensor 146 is provided, and the system sensor 146 is a flatness sensor 148. In this embodiment, the flatness sensor 148 may detect a flatness of the cast metal product 114, and the controller 138 optionally may control the dams 136 based on the detected flatness from the flatness sensor 148. In certain embodiments, the flatness (or cross-sectional) profile detected by the flatness sensor 148 may be used to predict a temperature profile of the cast metal product 114 and / or the molten metal. Various other types of sensors may be used as the at least one system sensor 146 as desired.

[0026] FIGS. 4-7 illustrate another example of a continuous casting system 400 with a continuous casting device 402 and a metal feeding system 404 according to embodiments. Similar to the casting device 102, the casting device 402 is a twin roll caster 406 with a frame 407 for supporting rolls similar to the rolls 108. However, in FIGS. 4-7, the rolls of the twin roll caster 406 have been omitted for clarity of the figures.

[0027] The metal feeding system 404 is similar to the metal feeding system 104 and includes an injector 416, a supply container 418, and a dam system 420. The injector 416 is substantially similar to the injector 116 except that the injector 416 has a different profile. The supply container 418 is substantially similar to the supply container 118 except that a shape and profile of the supply container 418 and of the receiving area 430 of the supply container 418 is different compared to the supply container 118.

[0028] The dam system 420 is similar to the dam system 120 and includes a plurality of dams 436A-E and a controller 438 operably coupled to the dams 436A-E for vertically positioning the dams 436A-E within the receiving area 430. As best illustrated in FIGS. 5-7, similar to the controller 138, the controller 438 includes an actuator 440 mechanically coupling the controller 438 to each of the dams 436A-E. In the embodiment illustrated in FIGS. 4-7, the actuator 440 includes a motor 441 and a plurality of flexible shafts 443A-E. The motor 441 is illustrated as being supported on the frame 407; however, in other embodiments, the motor 441 may be provided in various locations as desired. Each flexible shaft 443A-E mechanically and operably connects the motor 441 with a corresponding dam 436A-E such that the dams 436A-E are independently controllable.

[0029] Referring back to FIGS. 1-3, a method of controlling a molten metal distribution to the continuous casting device 102 using the metal feeding system 104 is discussed in detail below. In certain embodiments, the method includes supplying a molten metal, such as a molten aluminum alloy, to the supply container 118. In some embodiments, the method includes initially receiving the molten metal in the introduction portion 132 of the supply container 118 such that the molten metal flows from the introduction portion 132 to the main portion 134. The method includes at least partially blocking the flow of the molten metal through the receiving area 130 of the supply container 118 using dams 136 to control the metal distribution to the injector 116. The method includes introducing the molten metal into the gap 112 of the casting device 102 through the tip 122 of the injector 116 and casting the molten metal into the cast metal product 114 using the casting device 102.

[0030] According to the invention, the method includes controlling, using the controller 138, the vertical positions of the dams 136 to control the metal distribution and / or the temperature distribution of the molten metal introduced into the gap 112. In some embodiments, the method includes vertically raising a particular dam 136 to increase a flow of metal and / or increase a temperature of the molten metal downstream from the particular dam 136 and vertically lowering a particular dam 136 to decrease a flow of metal and / or decrease a temperature of the molten metal downstream from the particular dam 136. In some embodiments, controlling the vertical positions of the dams 136 includes independently controlling each dam 136 of the plurality of dams 136.

[0031] According to the invention, controlling the dams 136 includes receiving a temperature of the molten metal downstream from a particular dam 136 from a corresponding temperature sensor 142, and controlling the particular dam 136 based on the detected temperature from the corresponding temperature sensor 142. As non-limiting examples, the method may include controlling the dam 136A based on a detected temperature from the temperature sensor 142A, controlling the dam 136B based on a detected temperature from the temperature sensor 142B, controlling the dam 136C based on a detected temperature from the temperature sensor 142C, controlling the dam 136D based on a detected temperature from the temperature sensor 142D, and / or controlling the dam 136E based on a detected temperature from the temperature sensor 142E.

[0032] In various embodiments, controlling the dams 136 based on the detected temperatures from the temperature sensors 142 may include comparing the detected temperatures to predetermined temperatures corresponding to a particular profile of the cast metal product 114, and controlling the dams 136 based on any differences between the detected and predetermined temperatures. In certain embodiments, controlling the dams 136 may include controlling the dams 136 such that the molten metal supplied to the casting device has a desired temperature profile or distribution along the width of the molten metal introduced into the gap 112. The desired temperature profile or distribution may be a uniform temperature profile or distribution in some embodiments; however, in other embodiments, the method includes controlling the dams 136 to provide a nonuniform temperature profile or distribution along the width of the molten metal introduced into the gap 112. In some embodiments, the method optionally includes predicting, by the controller 138, a temperature profile of the cast metal product 114 and / or molten metal based on a detected flatness profile of the cast metal product. Optionally, the method may include comparing the predicted temperature profile to a desired temperature profile and controlling the vertical position of one or more of the dams 136 based on a difference between the predicted temperature profile and the predetermined temperature profile.

[0033] Optionally, the method includes controlling the vertical position of one or more dams 136 based on information from the at least one system sensor 146. As a non-limiting example, the method may include receiving, by the controller 138, a detected flatness profile of the cast metal product from the at least one system sensor 146, comparing the detected flatness profile to a desired flatness profile, and controlling one or more dams 136 based on any difference between the detected flatness profile and the desired flatness profile.

[0034] As mentioned, the systems and method provided herein may allow for improved distribution of molten metal to a continuous casting device, such as a twin roll caster, which may allow for improved control of the quality of the cast metal product. The systems and method provided herein may allow for improved control in an otherwise difficult working environment that is in close proximity to molten metal and in close proximity to a continuous casting device. Various other benefits and advantages may be realized with the systems and methods discussed herein.

[0035] The subject matter of embodiments is described herein with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as "up," "down," "top," "bottom," "left," "right," "front," and "back," among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing. Throughout this disclosure, a reference numeral with a letter refers to a specific instance of an element and the reference numeral without an accompanying letter refers to the element generically or collectively. Thus, as an example (not shown in the drawings), device "12A" refers to an instance of a device class, which may be referred to collectively as devices "12" and any one of which may be referred to generically as a device "12". In the figures and the description, like numerals are intended to represent like elements. As used herein, the meaning of "a," "an," and "the" includes singular and plural references unless the context clearly dictates otherwise.

[0036] In this description, reference is made to alloys identified by AA numbers and other related designations, such as "series" or "7xxx." For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot," both published by The Aluminum Association.

[0037] As used herein, a plate generally has a thickness of greater than about 15 mm. For example, a plate may refer to an aluminum product having a thickness of greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm. As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm. For example, a shate may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm. As used herein, a sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, a sheet may have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).

[0038] As used herein, terms such as "cast metal product," "cast product," "cast aluminum alloy product," and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting), semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.

[0039] The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the scope of the invention, as defined by the appended claims. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.

Claims

1. A metal feeding system (104; 404) comprising: an injector (116; 416) for distributing a molten metal into a movable mold (108); a supply container upstream from the injector (116; 416) and defining a receiving area (130; 430) configured to receive the molten metal; and a dam system (120; 420) comprising: at least one dam (136; 436) positionable within the receiving area (130; 430); and a controller (138; 438) operably coupled to the at least one dam (136; 436), the controller (138; 438) configured to vertically position the at least one dam (136; 436) within the receiving area (130; 430) for controlling a flow of molten metal from the receiving area (130; 430) to the injector (116; 416), wherein the at least one dam (136; 436) comprises a plurality of dams (136A-E; 436A-E) provided along at least a portion of a width of the receiving area (130; 430) and in a direction transverse to a flow direction of the molten metal from the receiving area (130; 430) to the injector (116; 416), wherein the controller (138; 438) is operably coupled to each dam (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E) and is configured to independently control a vertical position of each dam (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E), wherein the dam system (120; 420) further comprises a plurality of temperature sensors (142A-E), wherein each temperature sensor (142A-E) of the plurality of temperature sensors (142A-E) is communicatively coupled to the controller (138; 438) and is configured to detect a temperature of the molten metal downstream from a corresponding dam (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E), and wherein the controller (138; 438) is configured to independently control the vertical position of each dam (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E) based on the detected temperature of the molten metal from the corresponding temperature sensor (142A-E).

2. The metal feeding system (104; 404) of claim 1, wherein the controller (138; 438) is mechanically coupled to the at least one dam (136; 436).

3. The metal feeding system (104; 404) of claim 1, wherein the controller (138; 438) is configured to predict a temperature profile of a cast metal product based on a detected flatness profile of the cast metal product, compare the predicted temperature profile to a predetermined temperature profile, and control the vertical position of the at least one dam (136; 436) based on a difference between the predicted temperature profile and the predetermined temperature profile.

4. The metal feeding system (104; 404) of claim 1, wherein the temperature sensor (142A-E) is configured to detect the temperature of the molten metal upstream from a tip of the injector (116; 416).

5. The metal feeding system (104; 404) of claim 1, wherein the plurality of dams (136A-E; 436A-E) comprises at least five dams (136A-E; 436A-E).

6. A twin roll casting system (100; 400) comprising the metal feeding system (104; 404) of claim 1 and a twin roll caster (106; 406).

7. The twin roll casting system (100; 400) of claim 6, further comprising a flatness sensor (148) downstream from the twin roll caster (106; 406)configured to detect a flatness profile of a cast metal product downstream from the twin roll caster (106; 406), wherein the flatness sensor (148) is communicatively coupled to the controller (138; 438), and wherein the controller (138; 438) is configured to control a vertical position of the at least one dam (136; 436) at least partially based on the detected flatness profile.

8. A dam system (120; 420) for a metal feeding system (104; 404), the dam system (120; 420) comprising: a plurality of dams (136A-E; 436A-E); a controller (138; 438) operably coupled to each dam (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E), wherein the controller (138; 438) is configured to control a vertical position of each dam (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E) independently from the other dams (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E); and a plurality of temperature sensors (142A-E), wherein each temperature sensor (142A-E) of the plurality of temperature sensors (142A-E) is configured to detect a temperature of a molten metal downstream from a corresponding dam (136A-E; 436A-E), wherein each temperature sensor (142A-E) of the plurality of temperature sensors (142A-E) is communicatively coupled to the controller (138; 438), and wherein the controller (138; 438) is configured to control each dam (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E) based on the detected temperature of the molten metal from the corresponding temperature sensor (142A-E).

9. The dam system (120; 420) of claim 8, wherein the controller (138; 438) is mechanically coupled to each dam (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E).

10. The dam system (120; 420) of claim 8, wherein the controller (138; 438) is configured to control the vertical position of each dam (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E) for controlling a temperature profile of a molten metal.

11. A method of controlling a molten metal distribution to a continuous casting device, the method comprising: at least partially blocking a flow of a molten metal from a receiving area (130; 430) to an injector (116; 416) using at least one dam (136; 436) in the receiving area (130; 430); detecting a temperature of the molten metal downstream from the at least one dam (136; 436); and controlling a vertical position of the at least one dam (136; 436) based on the detected temperature, wherein the at least one dam (136; 436) comprises a plurality of dams (136A-E; 436A-E), and wherein detecting the temperature of the molten metal comprises detecting the temperature of the molten metal downstream from each dam (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E), wherein controlling the vertical position of the at least one dam (136; 436) comprises independently controlling the vertical position of each dam (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E) based on the detected temperature corresponding to the particular dam (136A-E; 436A-E) of the plurality of dams (136A-E; 436A-E).

12. The method of claim 11, further comprising predicting a temperature profile of a cast metal product based on a detected flatness profile of the cast metal product, comparing the predicted temperature profile to a predetermined temperature profile, and controlling the vertical position of the at least one dam (136; 436) based on a difference between the predicted temperature profile and the predetermined temperature profile.

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