System and method for monitoring metal level during casting

Abstract

To provide a monitoring system that may monitor the level of molten metal in a mold.SOLUTION: The monitoring system may include a camera and a computer system. The camera may be positioned to capture or detect optical data associated with one or more molds positioned in a casting environment, and send the optical data to the computer system. For example, the computer system may determine the level of the molten metal in the mold. The level of the molten metal in the mold may be compared with a baseline level. The computer system may generate operating instructions based on the comparison between the current level and the baseline level. The operating instructions may be used to adjust the casting process.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of and priority to U.S. Provisional Patent Application No. 62 / 705,948, entitled "MONITORING Metal Level During Casting," filed July 23, 2020, the entire contents of which are incorporated herein by reference for all purposes.

[0002] The present disclosure relates generally to metal casting, and more particularly, to associated processes and systems for monitoring the metal casting process. [Background technology]

[0003] Molten metal can be deposited into a mold to create metal ingots. These metal ingots may be formed using, for example, direct chill (DC) casting or electromagnetic casting (EMC). In DC casting, the molten metal is typically poured into a shallow, water-cooled mold. The mold may include a bottom block mounted on a telescoping hydraulic table to form a false bottom. The bottom block may be placed at or near the bottom of the mold before the molten metal is deposited into the mold. Once the molten metal is deposited into the mold, it fills the mold cavity and the exterior and bottom of the mold may be cooled. As the molten metal cools, it may begin to solidify and form a shell of solid or semi-solid metal around the molten core. As the bottom block descends, additional molten metal may be delivered to the mold cavity.

[0004] Before, during, and after the casting process, the mold and metal ingot may be monitored by one or more sensors. For example, a metal level sensor may measure the height of the molten metal in the mold. Many of these sensors are located in and around the mold, and are often in physical contact with the ingot or mold. To mitigate the risk of workers entering the casting environment and sensors contacting the ingot, it may be desirable to monitor the casting process from outside the casting environment using a system that does not contact the ingot. Summary of the Invention

[0005] The terms "embodiments" and "similar terms" are intended to broadly refer to all of the subject matter of the present disclosure and the following claims. Statements containing these terms should not be understood to limit the subject matter described herein, nor should they limit the meaning or scope of the following claims. The embodiments of the present disclosure contained herein are defined by the following claims, not this Summary of the Invention. This Summary is a high-level overview of various aspects of the present disclosure, and introduces some of the concepts that are further described in the Detailed Description section below. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The subject matter should be understood by reference to the entire specification of this disclosure, any or all drawings, and appropriate portions of each claim.

[0006] Certain examples herein feature systems and methods for monitoring a casting system during a casting process. Various examples utilize a casting system including a trough that deposits molten metal into one or more molds during the casting process. At least one of the molds may have multiple side walls that span between a top and a bottom of the mold. The top and bottom of the mold are open to allow molten metal to be deposited by a trough through the open top and solidifying metal to drain out the open bottom. The system may include one or more cameras with at least one camera having a field of view that includes at least a portion of the mold. For example, the field of view of the one or more cameras may include the top of the mold. A computer system may be used to detect one or more events during a casting operation, such as a level of metal in the mold or a distance between a bottom block and a portion of a metal ingot. The computer system may determine appropriate actions and / or alerts based on one or more of the detected events.

[0007] In various examples, a system for monitoring a casting operation is provided. The system may include a mold having a mold wall defining an opening for receiving molten metal, a trough configured to deposit molten metal into the mold opening during a casting operation, a camera having a field of view that includes at least a portion of the mold wall and configured to acquire optical data associated with the portion of the mold wall, and a controller including a processor configured to execute instructions stored in a non-transitory computer readable medium of a memory. The controller may cause the processor to perform processor operations including receiving the optical data associated with the portion of the mold wall and determining a level of molten metal in the mold based on the optical data.

[0008] In various examples, a method of monitoring a mold is provided. The method may include initiating a casting operation using a casting system. The casting system may include a mold including a mold wall defining a mold opening. The casting operation may cause molten metal to flow into the mold opening. The monitoring method may also include obtaining, using a camera, first optical data associated with a portion of the first mold wall and determining a level of molten metal in the mold based on the first optical data.

[0009] In various examples, a system for monitoring a mold is provided. The system may include a mold including a mold wall defining an opening for receiving molten metal, a camera having a field of view that includes at least a portion of the mold wall and configured to acquire optical data associated with the portion of the mold wall, and a controller including a processor configured to execute instructions stored in a non-transitory computer-readable medium of a memory. The controller may cause the processor to perform processor operations including acquiring first optical data associated with the portion of the mold wall and determining a level of molten metal within the mold based on the first optical data.

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

[0011] This specification refers to the following accompanying figures, in which the use of like reference numbers in different figures is intended to indicate the same or similar components. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a diagram of a system for monitoring a casting environment, according to various embodiments. [Diagram 2] 2 is a partial cross-sectional view of the monitoring system of FIG. 1 in accordance with various embodiments. [Diagram 3] FIG. 2 is a partial top view of the monitoring system of FIG. 1, in accordance with various embodiments. [Figure 4] 2 illustrates an example computer system for use with the monitoring system of FIG. 1, according to various embodiments. [Diagram 5] 2 illustrates a portion of an example casting system for use with the monitoring system of FIG. 1, according to various embodiments. [Figure 6] 2 illustrates a top view of a portion of an example casting system for use with the monitoring system of FIG. 1, in accordance with various embodiments. [Figure 7] 1 is a flowchart depicting an example of a process for using a monitoring system, according to various embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] As used herein, the terms "invention," "the invention," "this invention," and "the present invention" are intended to broadly refer to all of the subject matter of this patent application and the claims that follow. Statements containing these terms should be understood not to limit the subject matter described herein or the meaning or scope of the claims that follow. Although the subject matter of the embodiments of the present invention has been described herein with specificity to meet statutory requirements, 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 construed as implying a particular order or arrangement among the various steps or elements unless the order of individual steps or arrangement of elements is expressly described. As used herein, the meanings of "a," "an," and "the" include singular and plural references unless the context clearly dictates otherwise.

[0014] Although certain aspects of the present disclosure may be suitable for use with any type of material, such as metal, certain aspects of the present disclosure may be particularly suitable for use with aluminum.

[0015] All ranges disclosed herein should be understood to include any and all subranges subsumed therein. For example, a stated range "1 to 10" should be considered to include any and all subranges between (and including) the minimum value of "1" and the maximum value of "10," i.e., all subranges beginning with a minimum value of 1 or more (e.g., 1 to 6.1) and ending with a maximum value of 10 or less (e.g., 5.5 to 10).

[0016] The following examples serve to further explain the invention but at the same time do not constitute any limitation thereof, but on the contrary it is to be clearly understood that they also refer to various embodiments, modifications thereof and equivalents which may occur to those skilled in the art after reading the description herein without departing from the spirit of the invention.

[0017] FIG. 1 illustrates a monitoring system 100 for monitoring a casting environment including one or more molds 102 and associated components, according to certain embodiments. While the monitoring system 100 may include any number of components, in various embodiments, the monitoring system 100 includes a trough 104 disposed over the one or more molds 102. The trough 104 may include one or more openings for depositing molten metal 106 into the molds 102. The molten metal 106 may cool into a solid or semi-solid ingot 108 during the casting process. One or more cameras 110 may be disposed in the casting environment to detect or acquire optical data related to the one or more components. For example, the camera 110 may acquire optical data related to the molten metal 106. The optical data may be processed using a computer system 112 to monitor one or more casting operations.

[0018] The monitoring system 100 may be used to remotely monitor various components used in the casting process. For example, a camera, such as camera 110, may be used to monitor the casting environment and / or the cast parts. Remote monitoring allows a user to remain outside of the casting environment or enter the casting environment for a shorter period of time than would otherwise be required. Additionally, multiple aspects of the casting environment may be monitored simultaneously, reducing the need for additional monitoring systems. Remote monitoring may also allow some or all of the monitoring system 100 to be located further away from one or more heat sources in the casting environment. For example, instead of placing a detector near or mounting a detector on the mold 102, which may be exposed to extreme heat from the molten metal 106, the camera 110 may be located in a cooler environment away from the mold 102 and / or molten metal 106. Locating the monitoring equipment away from heat sources may additionally or alternatively reduce the number of repairs or replacements, saving time and money.

[0019] The mold 102 may be placed in a casting environment to receive the molten metal 106 into the mold opening. The mold 102 may include a material capable of withstanding the heat of the molten metal 106 as it cools to form the ingot 108. For example, the mold 102 may include graphite. The mold 102 may have any suitable shape or design for receiving and cooling the molten metal 106. In various embodiments, the mold 102 may have a rectangular cross-section with four mold walls, an open top for receiving the molten metal 106, and an open bottom to allow the ingot 108 to exit. In some embodiments, the mold 102 may include or cooperate with a bottom block 114 for forming the ingot 108, as is common for molds 102 used in direct chill casting. The bottom block 114 may be movable or stationary. In some embodiments, the bottom block 114 may be a starting head mounted on a telescoping hydraulic table. In alternative embodiments, the mold 102 may be of any type and shape suitable for casting the molten metal 106 .

[0020] In various embodiments, the mold 102 can additionally or alternatively aid in cooling the molten metal 106 to form the ingot 108. In a non-limiting example, the mold 102 is a water-cooled mold. For example, the mold 102 can include a cooling system that uses one or more of air, glycol, or any suitable medium for cooling. In various embodiments, the mold 102 can have heated walls that slow the cooling of the mold walls (e.g., an Ohno Continuous Caster (OCC) mold can be used).

[0021] The ingot 108 may be formed by molten metal 106 cooling against the walls of the mold 102. For example, molten metal 106 may be deposited into the mold 102 and begin to solidify, forming the ingot 108. The bottom block 114 may be steadily lowered while additional molten metal 106 is added to the top of the mold 102, lengthening the ingot 108.

[0022] The molten metal 106 and / or ingot 108 may be formed from any metal or combination of metals that can be heated to a melting temperature. In a non-limiting example, the molten metal 106 and / or ingot 108 includes aluminum. In various embodiments, the molten metal 106 and / or ingot 108 may include iron, magnesium, or a combination of metals.

[0023] As described above, the molten metal 106 may be deposited into the one or more dies 102 by one or more troughs 104 disposed adjacent to the dies. The troughs 104 may include one or more openings for depositing the molten metal 106 into the one or more dies 102. In various embodiments, the troughs 104 may be disposed over the one or more dies 102 and may deposit the molten metal 106 into the one or more dies 102 from one or more openings. The troughs 104 may be of any size and shape suitable for containing and distributing the molten metal 106. As illustrated, the troughs 104 have a rectangular shape with a U-shaped channel for containing the molten metal 106. In some embodiments, the troughs 104 may have any suitable size and shape for depositing the molten metal 106 into the one or more dies 102.

[0024] In various embodiments, the trough 104 may include a flow control device 116. The flow control device 116 may control the flow rate of the molten metal 106 from the trough 104 to the one or more dies 102. As described below with respect to FIGURE 2, the flow control device 116 may include a pin disposed in an opening to control the flow of the molten metal 106 to the one or more dies 102.

[0025] One or more cameras 110 may be positioned in the casting environment to acquire or detect optical data. In various embodiments, the cameras 110 may be positioned to detect optical data related to one or more molds 102. The cameras 110 may be or include optics capable of acquiring still images, video images, thermal images, infrared images, x-rays, or any suitable optical data. In various embodiments, the cameras 110 may transmit the optical data to a computer system 112 for processing. In some embodiments, the cameras 110 may be or include components that allow some or all of the optical data to be processed by the camera.

[0026] The camera 110 may have a field of view 118 that includes at least a portion of the mold 102. In some embodiments, the camera 110 may be movable or repositionable to change the field of view 118. For example, the camera 110 may swivel to detect optical data related to two adjacent molds 102. The camera 110 may be positioned facing one or more of the molds 102 or may otherwise have a field of view 118 that includes at least a portion of the mold 102. In various embodiments, the camera 110 is positioned above the mold 102 with a field of view 118 that includes at least a portion of the top of the mold 102. The camera 110 may additionally or alternatively be positioned below the mold 102 with a field of view that includes at least a portion of the bottom of the mold 102.

[0027] In various embodiments, the camera 110 may be positioned in any suitable orientation to have a field of view 118 that includes the casting environment and / or any suitable components disposed within or adjacent to the casting environment. For example, the camera 110 may have a field of view 118 that includes the casting environment and a portion of the mold 102 disposed in the casting environment. The camera 110 may be positioned within the casting environment or outside of the casting environment. In further embodiments, the orientation of the camera 110 is adjustable to include the casting environment and / or any suitable components disposed within or adjacent to the casting environment.

[0028] The surveillance system 100 may include multiple cameras 110 operating in tandem. The multiple cameras 110 may be positioned to have adjacent or overlapping fields of view 118. For example, two cameras 110 may be mounted at different heights above the mold 102 and may have overlapping fields of view 118 of the mold 102. As another example, two or more cameras 110 may be mounted such that each camera 110 has a field of view 118 of a portion of one side of the mold 102. The fields of view 118 may be combined to form an image of an entire side of the mold 102 or other collective area of ​​interest.

[0029] The computer system 112 may receive the optical data from the camera 110. The computer system 112 may include hardware and software for executing computer-executable instructions. For example, the computer system 112 may include a memory, a processor, and an operating system for executing computer-executable instructions (FIG. 4). The computer system 112 may have hardware or software that allows it to communicate with other devices via a wired or wireless connection (e.g., Bluetooth). The computer system 112 may communicate with one, any combination, or all of the flow controller 116, the camera 110, or any other suitable components associated with the casting environment.

[0030] In various embodiments, computer system 112 may be in a single physical location. For example, computer system 112 may be hardware and software located in the same manufacturing facility as one or more molds 102 and communicating with camera 110 via a local communications network (e.g., Wi-Fi or Bluetooth). In some embodiments, one or more computer systems 112 may be located in multiple physical locations and communicate with camera 110 via long-range communications (e.g., Internet, radio waves, or satellite). For example, computer system 112 may be a cloud computing system that includes any number of Internet-connected computing components.

[0031] The computer system 112 may include hardware and software that may enable it to receive optical data from the camera(s) 110, analyze the received data, and generate operating instructions for the casting operation. Some or all of these steps may be performed by a single computer system 112 or multiple computer systems.

[0032] In various embodiments, the computer system 112 may include hardware and software that may enable the execution of the steps of depositing molten metal 106 into the mold 102 as part of a casting operation, acquiring optical data related to the mold 102, determining the level of molten metal 106 within the mold 102, comparing the level of molten metal 106 to a baseline level, and generating operating instructions for the casting operation.

[0033] In various embodiments, computer system 112 can alert a user based on the optical data received from camera 110. For example, computer system 112 may activate an alarm in response to the optical data. The alarm may correspond to or include a bell, a light, a siren, a display, a speaker, or any other object capable of attracting the attention of a user or system and / or conveying information to a user or system.

[0034] In addition to or instead of activating an alarm, other actions may be prompted. In various embodiments, a change in the flow of molten metal 106 to one or more molds 102 may be introduced in conjunction with or in lieu of activating an alarm. For example, the flow control device 116 may be controlled to increase, decrease, or otherwise change the flow rate, amount, or other characteristic of the flow of molten metal 106 to the molds 102. In various embodiments, additionally or alternatively, a warning may be displayed, logged, transmitted, or otherwise communicated to a user or another aspect of the system (e.g., may be independent of activating an alarm or may be performed in conjunction with activating an alarm and / or a change in the flow of molten metal 106).

[0035] Referring to Figure 2, a partial cross-sectional view of the monitoring system 100 of Figure 1 is shown. This portion of the monitoring system 100 includes the mold 102, the camera 110, and the trough 104. The trough 104 may include a flow control device 116 for controlling the flow of molten metal from the trough into the mold 102. The flow control device 116 may include a pin 202 disposed in an opening 204. The pin 202 may be attached to a motor 206 for moving the pin relative to the opening 204.

[0036] The pin 202 may be positioned in an opening 204 in the trough 104. The opening 204 and / or the pin 202 may be tapered such that as the pin is moved downward relative to the opening, the annulus between the pin and the opening becomes smaller. The pin 202 may be raised and / or lowered to regulate the flow of molten metal 106 from the trough 104. For example, the pin 202 may be raised to increase the annulus between the pin and the opening 204, thereby increasing the amount of molten metal 106 flowing from the trough 104 (e.g., as shown by the solid lines). Additionally, the pin 202 may be lowered to reduce the annulus between the pin and the opening 204, thereby decreasing and / or stopping the flow of molten metal 106 from the trough 104 (e.g., as shown by the dashed lines).

[0037] Pin 202 can be raised and / or lowered by motor 206. In various embodiments, motor 206 may communicate with computer system 112 for automatic raising and / or lowering of pin 202. In various embodiments, pin 202 can be manually raised and / or lowered. In some examples, the manual raising and / or lowering of pin 202 may be facilitated by computer system 112. In some embodiments, pin 202 can automatically raise and / or lower to maintain the level of molten metal 106 within the mold 102 within a threshold range. Pin 202 may additionally or alternatively automatically raise and / or lower in response to detection of a gap between ingot 108 and bottom block 114. Further, pin 202 may automatically raise and / or lower in response to detection of one or more of mold leakage, mold cracking, mold dust, mold rust, mold misalignment, moisture within the mold, metal within the mold, platen engagement, platen position, platen drift, and / or failure of the cooling system.

[0038] In various embodiments, pin 202 can be lowered and / or raised based on one or more conditions of molten metal 106 and / or mold 102 (e.g., the pin can be moved rhythmically). For example, pin 202 may rise and fall in response to molten metal 106 being pulled away from mold 102. In some embodiments, pin 202 may rise and fall at time intervals to regulate the flow of molten metal 106 into mold 102. Rhythmically moving pin 202 may cause molten metal 106 to flow into mold 102 and disrupt the surface tension of the molten metal within mold 102. When the surface tension of molten metal 106 within mold 102 is disrupted, the molten metal may flow more easily along the surface of the molten metal within the mold. In further embodiments, flow control device 116 may additionally or alternatively include a valve, stop, funnel, or other suitable structure.

[0039] 3, an example of the field of view 118 of the camera 110 is shown. The field of view 118 may include the walls of the mold 102, the molten metal 106, and / or the ingot 108. As shown in the example of FIG. 3, the field of view 118 includes one side (e.g., the top) of the mold 102 and the entire circumference of that side of the mold 102. However, the field of view 118 may include a subportion of the circumference of the mold 102, portions of multiple molds, multiple sides of the mold 102, or multiple sides of multiple molds.

[0040] By way of example, the field of view 118 is shown as being divided into four quadrants (e.g., I, II, III, IV). However, the field of view 118 may include more or fewer quadrants. A single camera 110 may have a field of view 118 that includes all four quadrants. However, a single camera 110 may have a field of view 118 that corresponds to a single quadrant or a subset of quadrants. Additionally or alternatively, a single camera 110 may have a field of view 118 that corresponds to a combination of quadrants. In some embodiments, a single camera 110 may have multiple fields of view 118 (e.g., each quadrant is a different field of view 118) that the camera 110 can switch between. For example, a movable camera 110 may switch between fields of view 118 as the camera 110 pans around the top of the mold 102. In various embodiments, the quadrants may include markings that correspond to coordinates of locations on the ingot 108 and / or mold 102.

[0041] FIG. 4 is an example of a computer system 400 for use with the monitoring system 100 shown in FIG. 1. In various embodiments, the computer system 400 includes a controller 410 that is digitally implemented and programmable using conventional computer components. The controller 410 may be used in connection with a particular example (including, for example, an appliance as shown in FIG. 1) to execute the processes of such an example. The controller 410 includes a processor 412 that executes code stored in a tangible computer-readable medium in a memory 418 (or elsewhere in a portable medium, server, or cloud, among other media) to cause the controller 410 to receive and process data, perform actions, and / or control components of an appliance as shown in FIG. 1. The controller 410 may be any device capable of executing code, which is a series of instructions to process data and perform actions, such as controlling industrial equipment. As non-limiting examples, the controller 410 may take the form of a digitally implemented and / or programmable PID controller, a programmable logic controller, a microprocessor, a server, a desktop or laptop personal computer, a laptop personal computer, a handheld computing device, and a mobile device.

[0042] Examples of the processor 412 include any desired processing circuit, application specific integrated circuit (ASIC), programmable logic circuit, state machine, or other suitable circuit. The processor 412 may include one processor or any number of processors. The processor 412 may access the code stored in the memory 418 via the bus 414. The memory 418 may be any non-transitory computer-readable medium configured to tangibly embody the code and may include electronic, magnetic, or optical devices. Examples of the memory 418 include random access memory (RAM), read only memory (ROM), flash memory, floppy disk, compact disk, digital video device, magnetic disk, ASIC, configured processor, or other storage device.

[0043] The instructions may be stored in the memory 418 or the processor 412 as executable code. The instructions may include processor-specific instructions generated by a compiler and / or interpreter from code written in any suitable computer programming language. The instructions may be in the form of an application including a series of set points, parameters, and programmed steps that, when executed by the processor 412, enable the controller 410 to monitor and control various components of the surveillance system 100. For example, the instructions may include instructions for a machine vision application.

[0044] The controller 410 shown in FIG. 4 includes an input / output (I / O) interface 416 through which the controller 410 can communicate with devices and systems external to the controller 410, including components such as the flow control device 116 or the camera 110. The input / output (I / O) interface 416 may also receive input data from other external sources, as needed. Such sources may include control panels, other human / machine interfaces, computers, servers, or other equipment that may send instructions and parameters to the controller 410 to control its performance and operation, store and facilitate programming of applications that enable the controller 410 to execute instructions in applications and monitor various components of the casting process, as well as other sources of data necessary or useful for the controller 410 to perform its functions. Such data may be communicated to the input / output (I / O) interface 416 via a network, hardwire, wireless, bus, or otherwise desired.

[0045] 5 and 6, various fields of view 118 of the camera 110 are shown, according to various embodiments. FIG. 5 shows an isometric view of the mold 102, molten metal 106, ingot 108, and various fields of view 118 that may be used as part of the monitoring system 100. The fields of view 118 may be from a single camera 110 or from multiple cameras 110. The fields of view 118 may include some or all of the mold 102. For example, the fields of view 118 may include a portion of the walls of the mold 102 (e.g., 118A), the walls of the mold (e.g., 118B), or the top of the mold (e.g., 118C). The fields of view 118 may allow for monitoring the level of the molten metal 106 in the mold 102 without having to place a sensor around the mold. For example, a conventional molten metal level sensor may have physical components attached to the mold 102 and / or may contact the molten metal 106. The components located around the mold 102 may deteriorate over time and require replacement or repair, which can be time-consuming and costly. Additionally, placing sensors around the mold 102 often requires a user to enter the casting environment to place the sensor. Using a camera 110 with a field of view 118 may allow the level of molten metal 106 to be monitored without the need to contact the mold and / or the molten metal. Additionally, the level of molten metal 106 may be monitored without a user entering the casting environment.

[0046] The field of view 118 may be located on a portion of the mold 102 that includes a mark 502, such as an indicia or scale. The mark 502 may assist in determining the level of the molten metal 106 within the mold. The mark 502 is visible to a number of cameras 110 positioned around the mold 102 (e.g., from a top view shown in FIG. 6 ). The level of the molten metal 106 within the mold 102 may additionally or alternatively be determined from a top 506 of the mold 102.

[0047] In various embodiments, one or more of the fields of view 118 may be adjusted. For example, the field of view 118 may include a first wall of the mold 102 and may be adjusted and moved toward a second wall of the mold. Additionally, the field of view 118 may be adjusted to include some of the top of the mold 102. For example, the field of view 118 may include multiple walls of the mold 102 and may be adjusted to include a portion of a wall of the mold, such as the portion that includes the mark 502.

[0048] FIG. 6 is a top view of the mold 102 including multiple fields of view 118. The fields of view 118 are the same as those shown in FIG. 5, but the fields of view 118 may differ depending on the position of the camera 110 relative to the mold 102. In various embodiments, the marks 502 are visible in the top view. The fields of view 118 in the top view may be used to determine the level of the molten metal 106 in the mold. For example, the computer system 112 may determine the height of the molten metal 106 in the mold based on the optical data received from one or more of the fields of view 118. In various embodiments, the cameras 110 may be positioned at multiple angles (e.g., one angle shown in FIG. 5 and another angle shown in FIG. 6). The cameras 110 positioned at multiple angles may be used together to determine the height of the molten metal 106 in the mold 102.

[0049] Referring to FIG. 7, a flow chart illustrating an example of a process 700 for using the monitoring system 100 is shown. Some or all of the process 700 (or any other process described herein or variations and / or combinations thereof) may be executed under the control of one or more computer systems comprised of executable instructions, and may be implemented as code (e.g., executable instructions, one or more computer programs, or one or more applications) that executes collectively on one or more processors, by hardware, or by a combination thereof. The code may be stored in a computer-readable storage medium, for example, in the form of a computer program including a plurality of instructions executable by one or more processors. The computer-readable storage medium may be non-transitory. Also, unless otherwise specified, the acts shown in the process are not necessarily executed in the order shown, and / or some acts may be omitted in an embodiment.

[0050] The process 700 may include, at 702, depositing a metal, such as molten metal 106, into one or more molds, such as the mold 102. The molten metal 106 may be deposited into the mold 102 by a trough 104, as described herein. The trough 104 may deposit the molten metal 106 into the mold 102 through one or more openings in the trough 104. The amount or flow rate of the molten metal 106 entering the mold 102 may be regulated by controlling a flow controller 116. The molten metal 106 may enter the mold 102 through an opening in the mold 102. The molten metal 106 contained in the mold 102 may contact one or all of the walls of the mold 102. The temperature of the molten metal 106 decreases after entering the mold 102, and the molten metal 106 may cool and become a solid or semi-solid ingot 108.

[0051] The process 700 may include, at 704, receiving optical data related to the mold 102. The optical data may be acquired or detected using a camera, such as the camera 110. The camera 110 may have a field of view 118 that includes one or more molds 102. In various embodiments, the field of view 118 includes one or more walls of the mold 102 and / or the mark 502. The multiple cameras 110 may be positioned to have overlapping fields of view 118, a single camera may have multiple fields of view, or multiple cameras may have individual fields of view. The camera 110 may be positioned to acquire or detect optical data related to the mold 102 and / or the molten metal 106. For example, the camera 110 may acquire optical data related to a level of molten metal in the mold 102. The computer system 112 may receive the optical data from the camera 110 and / or a database. For example, the computer system 112 may receive the optical data from a database that includes optical data related to different molds.

[0052] The optical data may include the height of the walls of the mold 102 that are visible to the camera 110. The mark 502 may aid in measuring the height of the walls of the mold 102. For example, the mark 502 may include indicia and / or a scale that may be detected by the camera 110. The mark 502 may include an indication of how much of the height of the walls of the mold 102 is visible. In various embodiments, the mold 102 may include a texture and / or design that aids in detecting the height of the walls of the mold 102 that are visible. For example, the mold 102 may include a paint that is detectable by the camera 110.

[0053] The process 700 may include, at 706, determining the level of the molten metal 106 in the mold 102. Determining the level of the molten metal 106 may include using optical data acquired by the camera 110. However, the level of the molten metal 106 may also be determined using data received from a database. The level of the molten metal 106 may be determined using the computer system 112. In various embodiments, the level of the molten metal 106 in the mold may be determined using the visible height of the walls of the mold 102. For example, if the total height of the mold 102 (e.g., from the bottom 504 of the mold to the top 506 of the mold) is known, the height visible to the camera 110 may be subtracted to determine the level of the molten metal 106 in the mold 102. The level of the molten metal 106 in the mold 102 may be determined using the mark 502. For example, the mark 502 may include indicia (e.g., numbers) that can be interpreted by the computer system 112 to provide the level of the molten metal 106.

[0054] The process 700 may include, at 708, comparing the level of the molten metal 106 to a baseline level. The baseline level may be a range where the molten metal 106 should optimally remain. For example, the baseline level may be a range between 20 mm and 90 mm from the bottom 504 of the mold 102 (e.g., 20 mm, 30 mm, 40 mm, 50 mm, 50 mm, 70 mm, 80 mm, or 90 mm). However, the baseline level may be any suitable level or range from the top 506 and / or bottom 504 of the mold 102. The comparison may be performed by the computer system 112. The computer system 112 may receive the baseline level from a database and / or user input. The baseline level may vary by mold, metal, type of casting, or any suitable variable.

[0055] The process 700 may include generating, at 710, operational instructions for the casting operation. The operational instructions may include instructions to modify the casting process or may include instructions to continue the casting operation without modifications. The operational instructions may be based on the level of the molten metal 106 in the mold 102. For example, if it is determined that the molten metal 106 is below a baseline level in the mold 102, more molten metal may be added, for example, by operating the flow control device 116 through the trough 104. The operational instructions may be computer operational instructions and / or instructions to a user. For example, in response to the molten metal 106 exceeding an upper range of the baseline level, the operational instructions may instruct the flow control device 116 to stop the flow of molten metal and send a warning to the user that the flow of molten metal has stopped. In various embodiments, the operational instructions may include instructions to a user that cause the computer system 112 to automatically execute the instructions unless the user takes action. For example, the instructions may prompt the user to increase the flow rate of the molten metal 106, and if the user does not execute the instructions in a timely manner, the computer system 112 may automatically increase the flow rate of the molten metal 106.

[0056] All patents, publications, and abstracts cited above are incorporated herein by reference in their entirety. The foregoing description of the embodiments, including illustrative aspects of the embodiments, has been presented for purposes of illustration and description only and is not intended to be exhaustive or limited to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

[0057] (Aspect) Aspect 1 is a system for monitoring a mold, the system including: a mold including a mold wall defining an opening for receiving molten metal; a camera having a field of view that includes at least a portion of the mold wall and configured to acquire optical data related to the portion of the mold wall; and a controller including a processor configured to execute instructions stored in a non-transitory computer-readable medium of a memory, the controller causing the processor to perform processor operations including acquiring first optical data related to the portion of the mold wall and determining a level of the molten metal in the mold based on the first optical data.

[0058] Example 2 is the system of example (or any other preceding or subsequent example), individually or in combination, wherein acquiring the first optical data includes changing the field of view of the camera.

[0059] Example 3 is the system of example (s) 1 (or any preceding or subsequent example, individually or in combination), wherein the processor operations further include generating operating instructions for the casting operation.

[0060] Example 4 is the system of example 3 (or any preceding or subsequent example, individually or in combination), wherein the operational instructions are based at least on the level of the molten metal in the mold.

[0061] Example 5 is the system of example 3 (or any other preceding or subsequent example, individually or in combination), wherein the operating instructions include instructions for at least adjusting a flow rate of the molten metal into the mold opening.

[0062] Example 6 is the system of example (s) 1 (or any preceding or subsequent example, individually or in combination), wherein the processor operation further includes receiving second optical data relating to the portion of the mold wall and updating the level of the molten metal in the mold based on the second optical data.

[0063] Example 7 is the system of example (s) 1 (or any preceding or subsequent example, individually or in combination), wherein the portion of the mold wall includes an indicator that is visible to the camera.

[0064] Example 8 is the system of example (s) 7 (or any preceding or subsequent example, individually or in combination), wherein the indicator is configured to assist in determining the level of the molten metal in the mold.

[0065] Example 9 is the system of example 1 (or any preceding or subsequent example, individually or in combination), further including a trough configured to deposit the molten metal into the mold opening during the casting operation.

[0066] Example 10 is the system of example 9 (or any preceding or subsequent example, individually or in combination), wherein determining the level of the molten metal in the mold includes determining a height of the portion of the mold wall.

[0067] Example 11 is the system of example 3 (or any other preceding or subsequent example, individually or in combination), wherein the operating instructions include instructions for adjusting a flow rate of the molten metal into the mold opening.

[0068] Example 12 is the system of example 9 (or any other preceding or subsequent example, individually or in combination), wherein the level of the molten metal in the mold is in the range of 20 to 90 mm from the bottom of the mold.

[0069] Example 13 is a method of monitoring a mold, comprising: initiating a casting operation using a casting system including a mold having a mold wall defining a mold opening, the method including: initiating the casting operation to pour molten metal into the mold opening; acquiring first optical data associated with a portion of a first mold wall using a camera; and determining a level of the molten metal within the mold based on the first optical data.

[0070] Example 14 is the method of Example (s) 13 (or any other preceding or subsequent example), individually or in combination, further including generating operation instructions for one or more components for use with the casting operation based on the determining.

[0071] Example 15 is the method of example (s) 14 (or any other preceding or subsequent example, individually or in combination), wherein adjusting the casting operation includes altering a flow rate of the molten metal into the mold opening.

[0072] Example 16 is the method of example (s) 13 (or any preceding or subsequent example, individually or in combination), further including: acquiring second optical data related to a second portion of a second mold wall using the camera; and updating the level of the molten metal in the mold based on the second optical data.

[0073] Example 17 is the method of example (s) 16 (or any preceding or subsequent example, individually or in combination), wherein the first mold wall and the second mold wall are different mold walls.

[0074] Example 18 is the method of example (s) 13 (or any preceding or subsequent example, individually or in combination), wherein determining the level of the molten metal in the mold includes comparing a visible height of the portion of the mold wall to a known height.

[0075] Example 19 is the method of example (or multiple) 13 (or any preceding or subsequent example, individually or in combination), wherein determining the level of the molten metal in the mold includes distinguishing between the first optical data associated with the portion of the mold wall and second optical data associated with the molten metal.

Claims

1. 1. A system for monitoring a mold, comprising: a mold including a mold wall defining an opening for receiving molten metal; a camera having a field of view that includes at least a portion of a mold wall and configured to acquire optical data related to the portion of the mold wall; 1. A controller including a processor configured to execute instructions stored in a non-transitory computer readable medium in a memory, the controller comprising: acquiring first optical data associated with the portion of the mold wall; determining a level of the molten metal within the mold based on the first optical data; and the controller causing the processor to perform operations including: Including, the system.

2. The system of claim 1 , wherein acquiring the first optical data comprises changing the field of view of the camera.

3. The system of claim 1 , wherein the processor operations further comprise generating operating instructions for a casting operation.

4. The system of claim 3 , wherein the operational command is based at least on the level of the molten metal in the mold.

5. The system of claim 3 , wherein the operating instructions include instructions for at least adjusting a flow rate of the molten metal to the mold opening.

6. The processor operation includes: receiving second optical data relating to the portion of the mold wall; and updating the level of the molten metal in the mold based on the second optical data; and The system of claim 1 , comprising:

7. The system of claim 1 , wherein the portion of the mold wall includes an indicia that is visible to the camera.

8. The system of claim 7 , wherein the indicator is configured to assist in determining the level of the molten metal in the mold.

9. The system of claim 1 , further comprising a trough configured to deposit the molten metal within the mold opening during a casting operation.

10. The system of claim 9 , wherein determining the level of the molten metal in the mold comprises determining a height of the portion of the mold wall.

11. The system of claim 3 , wherein the operating instructions include instructions for adjusting the flow rate of the molten metal to the mold opening.

12. The system of claim 9, wherein the level of the molten metal in the mold is in the range of 20 to 90 mm from the bottom of the mold.

13. 1. A method for monitoring a mold, comprising: initiating a casting operation using a casting system including a mold having a mold wall defining a mold opening, the casting operation including flowing molten metal into the mold opening; acquiring first optical data relating to a portion of a first mold wall using a camera; determining a level of the molten metal within the mold based on the first optical data; and A method comprising:

14. The method of claim 13 , further comprising generating operation instructions for one or more components for use in the casting operation based on the determining.

15. The method of claim 14 , wherein adjusting the casting operation comprises altering a flow rate of the molten metal into the mold opening.

16. acquiring second optical data relating to a second portion of a second mold wall using the camera; and updating the level of the molten metal in the mold based on the second optical data; and The method of claim 13 further comprising:

17. The method of claim 16 , wherein the first mold wall and the second mold wall are different mold walls.

18. The method of claim 13 , wherein determining the level of the molten metal in the mold comprises comparing a visible height of the portion of the mold wall to a known height.

19. 14. The method of claim 13, wherein determining the level of the molten metal within the mold comprises distinguishing between the first optical data associated with the portion of the mold wall and second optical data associated with the molten metal.

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