On-line casting ingot profile measuring system and control

Abstract

A direct chill casting system includes a profile measuring system for measuring a profile of an ingot while the ingot is being cast by the direct chill casting system. A method of casting an ingot includes measuring a profile of the ingot using a profile measuring system while the ingot is being cast by a direct chill casting system.

Description

Patent Application Attorney Docket #: 108050-1446983 ON-LINE CASTING INGOT PROFILE MEASURING SYSTEM AND CONTROL REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No.63 / 582,065, filed on September 12, 2023, and entitled ON-LINE CASTING INGOT PROFILE MEASURING SYSTEM AND CONTROL, the content of which is hereby incorporated by reference in its entirety. FIELD OF THE INVENTION

[0002] This application relates to the casting of metals, and more particularly to systems and methods for controlling profiles of ingots during casting. BACKGROUND

[0003] In direct chill casting, molten metal is passed into a mold cavity with a false, or moving, bottom. As the molten metal enters the mold cavity, generally from the top, the false bottom lowers at a rate related to the rate of flow of the molten metal. The molten metal that has solidified near the sides can be used to retain the liquid and partially liquid metal in the metal sump. The metal can be 99.9% solid (e.g., fully solid), 100% liquid, and anywhere in between. The metal article resulting from the direct chill casting process can be referred to as an ingot. An ingot may have a generally rectangular cross section, although other cross sections may be used, such as circular or even non-symmetric. The term ingot, as used herein, can be inclusive of any direct chill cast metal article, including billets, as appropriate. Water, steam, and other aspects of the casting environment have traditionally prevented measurements and / or detection of the ingot during the casting process, and measurements and / or detection is performed after casting. Such traditional approaches may lead to increased material waste and lost productivity as defects, undesired profiles, etc. are only identified after the casting of the ingot. SUMMARY

[0004] 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 notPatent Application Attorney Docket #: 108050-1446983 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. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0005] According to certain embodiments, a direct chill casting system includes a profile measuring system for measuring a profile of an ingot while the ingot is being cast by the direct chill casting system.

[0006] According to some embodiments, a method of casting an ingot includes measuring a profile of the ingot using a profile measuring system while the ingot is being cast by a direct chill casting system.

[0007] According to various embodiments, a direct chill casting system includes an open-ended mold defining a mold cavity for receiving molten metal during casting of an ingot. The direct chill casting system further includes a bottom block to initially close a lower end of the open-ended mold and to move away from the lower end during casting of the ingot. The direct chill casting system may further include a profile measuring system for measuring a profile of the ingot during casting of the ingot.

[0008] Various implementations described herein can 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. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] 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.

[0010] FIG.1 is a side view of a metal casting system with a profile measuring system according to embodiments.

[0011] FIG. 2 is a top view of a mold of the metal casting system of FIG. 1 according to embodiments.Patent Application Attorney Docket #: 108050-1446983

[0012] FIG. 3 is a top view of the metal casting system of FIG. 1 with a plurality of ingots and with molds removed for clarity of the figure according to embodiments. DETAILED DESCRIPTION

[0013] Described herein are systems and methods for measuring a profile of an ingot during casting of the ingot. Compared to traditional approaches in which measurements and information were obtained after casting (or “off-line”), the systems and methods described herein obtain measurements during casting (or “on-line”), thereby providing improved detection of potential issues in the ingot and an improved response time to address such issues. In some embodiments, the systems and methods described herein may utilize the measured profile to control profile actuators (e.g., a casting mold, bottom block, etc.) during casting or to identify problems to be rectified for the next cast, thereby decreasing material waste, and providing an improved cast product compared to traditional approaches. In various embodiments, the systems and methods described herein may measure or detect the profile of the ingot during casting despite the relatively harsh casting environment (e.g., due to steam, water, etc.). Various other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting.

[0014] FIGS.1-3 illustrate an example of a direct chill (DC) casting system 100 for forming one or more ingots 102 and with a profile measuring system 104 according to embodiments.

[0015] As illustrated in FIG. 1, the DC casting system 100 generally includes an open-ended mold 106 and a bottom block 108. The mold 106 includes a top end 110, a bottom end 112, and mold walls 114 defining a mold cavity 116 as best illustrated in FIG. 2. The mold 106 may be surrounded by a cooling jacket through which a coolant 118, such as but not limited to water, is circulated to provide external cooling of the mold walls 114. The bottom block 108 may be initially positioned within or proximate to the bottom end 112 of the mold 106 to close the mold cavity 116 at the bottom end 112. In certain embodiments, the mold cavity 116 may be a generally rectangular shape, although in other embodiments the mold cavity 116 may have various shapes as desired.

[0016] In some embodiments, a casting table of the DC casting system 100 may include a single mold 106. However, in other embodiments, a casting table may include a plurality of molds 106 such that a plurality of ingots 102 may be cast concurrently. In such embodiments, and asPatent Application Attorney Docket #: 108050-1446983 illustrated in FIG. 2, the ingots 102 are generally formed at a plurality of locations (i.e., corresponding to each mold 106) and include at least a first position ingot 102A and a last position ingot 102B. The number of ingots 102 concurrently cast by the DC casting system 100 should not be considered limiting, and in various embodiments, the DC casting system 100 may include equipment to cast one ingot, two ingots, three ingots, four ingots, five ingots, and / or more than five ingots as desired.

[0017] During casting, molten metal may be introduced into the mold cavity 116 from a metal supply system. The molten metal may be various metals as desired, including but not limited to aluminum, aluminum alloys, steel, or other metals as desired. In some examples, the molten metal may be an aluminum or an aluminum alloy in the 1xxx series, 2xxx series, 3xxx series, 4xxx series, 5xxx series, 6xxx series, 7xxx series, 8xxx series and / or any other aluminum or aluminum alloy as desired. The metal supply system may include various equipment suitable for supplying the molten metal, including but not limited to a tundish or trough, which may supply molten metal through a spout into the mold cavity 116. Optionally, a flow controller may be included to control the flow of molten metal through the spout. Non-limiting examples of flow controllers include, but are not limited to, control pins, magnetic pumps, electric pumps, and / or any suitable device for controlling the flow of molten metal through the spout, including increasing the flow, decreasing the flow, and / or terminating the flow. Optionally, a skimming device may be provided to facilitate distribution of the molten metal.

[0018] During casting, the molten metal is introduced into the casting cavity 116, and as the molten metal begins to solidify within the mold, the bottom block 108 may be lowered at a casting speed (represented by arrow 122). A solidifying ingot 102 emerges from the bottom end 112 of the mold 106. Coolant 118, which may be the same as or different from the coolant 118 used to chill the mold walls 114, may be brought into direct contact with the outer surface 120 of the advancing ingot 102 directly below the mold 106, thereby causing direct chilling of the metal. This direct chilling of the surface 120 of the ingot 102 serves both to maintain the peripheral portion of the ingot 102 in solid state and to promote internal cooling and solidification of the ingot 102.

[0019] The profile measuring system 104 of the DC casting system 100 includes one or more detectors or sensors 124 for measuring and / or detecting a profile of the ingot 102 during casting of the ingot 102. In some embodiments, the sensors 124 are radar devices which measure and / orPatent Application Attorney Docket #: 108050-1446983 detect the profile of the ingot 102 using radar. Radar-based sensors 124 may allow for detection and / or measurement of the ingot 102 in the casting environment of the DC casting system 100 despite the relatively harsh environment due to steam, water, temperature, etc.

[0020] While a plurality of sensors 124 are illustrated in FIGS. 1-3, any number of sensors 124 may be utilized with the profile measuring system 104 as desired, including a single sensor 124, two sensors 124, three sensors 124, four sensors 124, five sensors 124, and / or more than five sensors 124 as desired.

[0021] The sensors 124 may be provided in various arrangements or configurations relative to other equipment of the DC casting system 100 and / or relative to the ingot 102 such that the sensors 124 may measure and / or detect the profile of the ingot 102 during casting. In certain embodiments, the profile measuring system 104 may measure at least one of the rolling faces 126, 128 of the ingot 102 (i.e., the faces defining the width 111 of the ingot 102), and in some embodiments the profile measuring system 104 may measure both rolling faces 126, 128. In such embodiments, at least one sensor 124 may be provided for measuring the rolling face 126 and at least one sensor 124 may be provided for measuring the rolling face 128. Additionally, or alternatively, the profile measuring system 104 may measure one or both sides 130, 132 of the ingot 102 defining the thickness of the ingot 102. In such embodiments, at least one sensor 124 may be provided for measuring the particular side 130, 132. In one non-limiting example, and as illustrated in FIG. 1, the profile measuring system 104 measures at least one of the rolling faces 126, 128 of the ingot 102.

[0022] Moreover, while the sensors 124 are illustrated as an array and horizontally aligned, they need not be in other embodiments. As non-limiting examples, when a plurality of sensors 124 are utilized, they may be arranged horizontally but not in alignment, arranged vertically and in alignment, arranged vertically but not in alignment, combinations thereof, and / or as otherwise desired. In other embodiments, both when a single sensor 124 is utilized and / or a plurality of sensors 124 are utilized, a position of a sensors 124 need not be fixed, and one or more sensors 124 may be adjustable via various actuators and / or other mechanisms such that their relative position is adjustable as desired. As non-limiting examples, one or more sensors 124 may be actuated and / or otherwise controlled to change their position and such that measurements may be made at different points and / or locations. In one non-limiting example, such adjustable positioningPatent Application Attorney Docket #: 108050-1446983 may allow for one or more sensors 124 to perform a plurality of measurements at different points during casting, such as but not limited to measuring butt swell occurring later in a casting process. In such examples, the sensor 124 may be actuated from a position more proximate to the mold 106 to a position downwards and suitable for measuring butt swell and then back upwards to a desired position. Various other position controls may be implemented as desired. In some non-limiting examples, movable and / or actuated sensors 124 may allow for fewer sensors 124 to be implemented within the system.

[0023] Referring to FIG. 3, in embodiments in which the DC casting system 100 concurrently casts a plurality of ingots 102, the profile measuring system 104 need not measure at least one rolling face 126, 128 of each ingot 102 (although it may in other embodiments). As a non-limiting example, the profile measuring system 104 may measure a first rolling face 126 (highlighted in red in FIG.3) of the first position ingot 102A and / or a second rolling face 128 (highlighted in red in FIG. 3) of the last position ingot 102B.

[0024] Various other arrangements of sensors 124 may be utilized as desired for measuring and / or detecting the profile of the ingot(s) 102 during casting, and the aforementioned examples should not be considered limiting.

[0025] In certain embodiments, in addition to the one or more sensors 124 for measuring and / or detecting the profile of the ingot(s) 102 using radar, the profile measuring system 104 may include a control system 134. The control system 134 may include a computer system and / or one or more processing units and / or one or more memory devices. The processing unit may be various suitable processing devices or combinations of devices including but not limited to one or more application specific integrated circuits, digital signal processors, digital signal processing devices, programmable logic devices, field programmable gate arrays, processors, controllers, micro- controllers, microprocessors, other electronic units, and / or a combination thereof. The one or more memory devices 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 diskPatent Application Attorney Docket #: 108050-1446983 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.

[0026] The control system 134 may be provided at various locations within the DC casting system 100 and / or the profile measuring system 104, including as a component of other equipment and / or as a stand-alone system or device. As a non-limiting example, while the control system 134 is illustrated as separate from the sensors 124, in some embodiments, the control system 134 (or sub- components thereof such as one or more processing units and / or one or more memory devices) may be components of one or more sensors 124.

[0027] In certain embodiments, the control system 134 optionally includes an associated user interface, including but not limited to a graphical user interface or a human machine interface, such that the control system 134 may obtain information from a user and / or provide information to the user. In such embodiments, the user interface and / or human machine interface may be on the control system 134 itself or may be at a location remote from the control system 134, such as on a user device, a dedicated user interface device, an operations control center remote from the profile measuring system 104, combinations thereof, and / or as otherwise desired.

[0028] The control system 134 may be communicatively coupled to at least the one or more sensors 124 such that the control system 134 receives the radar information and / or the profile information as measured and / or detected using radar. In some embodiments, the control system 134 may generate a control response for one or more profile actuators of the DC casting system 100 based on the measured and / or detected ingot profile. As non-limiting examples, the control system 134 may compare the measured profile of the ingot 102 obtained during casting with a target profile. In such examples, a control response for controlling one or more profile actuators may be generated based on a difference between the measured profile and the target profile. As another non-limiting example, the control system 134 may estimate and / or predict a final profile of the ingot by monitoring a change or trend of change in the profile and compare the estimated final profile with the target profile. In such an embodiment, a control response for controlling the one or more profile actuators may be generated based on a difference between the estimated finalPatent Application Attorney Docket #: 108050-1446983 profile and the target profile. Various other analysis may be performed by the control system 134 as desired and / or for generating various control responses as desired.

[0029] In some embodiments, the control response may be implemented during casting of the ingot 102. Additionally, or alternatively, the control system 134 may analyze the profile information to identify problems to be rectified in the casting of a next ingot 102, and the control response may be implemented in the casting of the next ingot 102.

[0030] The one or more profile actuators of the DC casting system 100 may be various devices or systems which may be controlled to control the profile of the ingot 102. In such embodiments, the control system 134 may be communicatively coupled with the one or more profile actuators such that the control system 134 may provide a control response for controlling the one or more profile actuators. Non-limiting examples of profile actuators include but are not limited to the mold 106, the bottom block 108, and / or cooling applied to the ingot 102. Non-limiting examples of control responses for the one or more profile actuators may include but are not limited to adjusting or controlling a shape of the mold 106 to adjust or control a shape of the mold cavity 116, adjusting or controlling the bottom block 108 to increase or decrease the casting speed, and / or adjusting or controlling a spray pattern or spray location of the coolant 118 on the ingot 102. Various other control responses may be implemented as desired. And as mentioned, the one or more profile actuators may be controlled during the casting of the ingot 102 and / or during a casting of a next ingot 102 as desired.

[0031] Additionally, or alternatively, the control system 134 may generate an alert to a user based on the measured and / or detected ingot profile. Such alerts may be auditory, visual, and / or as otherwise desired. The information provided to the user as part of the alert may include an indication that the detected profile is within tolerances of a target profile, the detected profile is outside of tolerances of the target profile but no action is required (e.g., the control system 134 is automatically adjusting), the detected profile is outside of tolerances of the target profile and action is required, and / or other alerts or notifications as desired.

[0032] Referring back to FIG. 1, a method of casting one or more ingots 102 may include supplying molten metal into the mold 106 of the DC casting system 100 and lowering the bottom block 108 such that the solidifying ingot 102 emerges from the mold 106. The method may include using the profile measuring system 104 to measure a profile of the ingot 102 while the ingot 102Patent Application Attorney Docket #: 108050-1446983 is being cast. In certain embodiments, the method includes measuring the profile of the ingot 102 using radar. Optionally, the method includes controlling a profile actuator of the DC casting system 100 based on the measured profile of the ingot 102 during casting of the ingot. In one non-limiting example, controlling the profile actuator includes controlling at least one of the mold 106 of the DC casting system 100 and / or the bottom block 108 of the DC casting system 100. Various other methods may be performed using the systems described herein, and the aforementioned method should not be considered limiting.

[0033] A collection of exemplary embodiments is provided below, including at least some explicitly enumerated as an “Illustration” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0034] Illustration 1. A direct chill casting system comprising a profile measuring system configured to measure a profile of an ingot while the ingot is being cast by the direct chill casting system.

[0035] Illustration 2. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the profile measuring system measures the profile of the ingot without physically contacting the ingot.

[0036] Illustration 3. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the profile measuring system is configured to measure the profile of the ingot using radar.

[0037] Illustration 4. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the profile measuring system comprises at least one sensor configured to measure the profile of the ingot using radar.

[0038] Illustration 5. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the at least one sensor is arranged relative to casting equipment of the direct chill casting system such that the at least one sensor measures the profile of a rolling face of the ingot defining a width of the ingot.Patent Application Attorney Docket #: 108050-1446983

[0039] Illustration 6. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the at least one sensor comprises a plurality of sensors.

[0040] Illustration 7. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the plurality of sensors are arranged relative to casting equipment of the direct chill casting system such that at least one sensor measures the profile of a first rolling face of the ingot and at least one sensor measures the profile of a second rolling face of the ingot.

[0041] Illustration 8. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, further comprising: a profile actuator configured to control a profile of the ingot; and a control system, wherein the control system is configured to generate a control response for the profile actuator based on the measured profile from the profile measuring system during casting.

[0042] Illustration 9. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the profile actuator comprises a mold of the direct chill casting system, and wherein the control response controls a shape defined by the mold.

[0043] Illustration 10. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the profile actuator comprises a bottom block of the direct chill casting system, and wherein the control response controls a speed of the bottom block.

[0044] Illustration 11. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the ingot is a first position ingot of a plurality of ingots being simultaneously cast by the direct chill casting system, and wherein the profile measuring system is configured to measure the profile of a first rolling face of the first position ingot and a second rolling face of a last position ingot of the plurality of ingots.

[0045] Illustration 12. A method of casting an ingot, the method comprising measuring a profile of the ingot using a profile measuring system while the ingot is being cast by a direct chill casting system.

[0046] Illustration 13. The method of any preceding or subsequent illustration or combination of illustrations, wherein measuring the profile comprises using radar to measure the profile of the ingot.Patent Application Attorney Docket #: 108050-1446983

[0047] Illustration 14. The method of any preceding or subsequent illustration or combination of illustrations, further comprising controlling a profile actuator of the direct chill casting system based on the measured profile of the ingot during casting of the ingot.

[0048] Illustration 15. The method of any preceding or subsequent illustration or combination of illustrations, wherein controlling the profile actuator comprises controlling at least one of a mold of the direct chill casting system or a bottom block of the direct chill casting system.

[0049] Illustration 16. A direct chill casting system comprising: an open-ended mold defining a mold cavity for receiving molten metal during casting of an ingot; a bottom block configured to initially close a lower end of the open-ended mold and to move away from the lower end during casting of the ingot; and a profile measuring system configured to measure a profile of the ingot during casting of the ingot.

[0050] Illustration 17. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, further comprising a controller configured to control at least one of the open-ended mold or the bottom block based on the measured profile of the ingot during casting.

[0051] Illustration 18. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the profile measuring system comprises a plurality of sensors arranged across a rolling face of the ingot and configured to measure the profile using radar.

[0052] Illustration 19. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the plurality of sensors are horizontally aligned.

[0053] Illustration 20. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the ingot is a first position ingot of a plurality of ingots, and wherein the profile measuring system is configured to measure the profile of a first rolling face of the first position ingot and a second rolling face of a last position ingot of the plurality of ingots.

[0054] Illustration 21. An ingot formed by the method of any preceding or subsequent illustration or combination of illustrations or using the direct chill casting system of any preceding or subsequent illustration or combination of illustrations.Patent Application Attorney Docket #: 108050-1446983

[0055] Illustration 22. The direct chill casting system of any preceding or subsequent illustration or combination of illustrations, wherein the at least one sensor is movable and / or actuated such that a position of the at least one sensor is adjustable.

[0056] As used herein, the terms “invention,” “the invention,” “this invention,” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0057] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “5xxx.” 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.

[0058] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0059] The elements included in the illustrations herein may not be drawn to scale. For example, figures depicting metal sumps may include exaggerated features for illustrative purposes.

[0060] The subject matter of embodiments of the present disclosure is described here 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,” “vertical,” “horizontal,” “lateral,” “longitudinal,” “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.Patent Application Attorney Docket #: 108050-1446983

[0061] The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0062] 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 can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. 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

Patent Application Attorney Docket #: 108050-1446983 CLAIMS That which is claimed:

1. A direct chill casting system comprising a profile measuring system configured to measure a profile of an ingot while the ingot is being cast by the direct chill casting system.

2. The direct chill casting system of claim 1, wherein the profile measuring system measures the profile of the ingot without physically contacting the ingot.

3. The direct chill casting system of claim 1, wherein the profile measuring system is configured to measure the profile of the ingot using radar.

4. The direct chill casting system of claim 1, wherein the profile measuring system comprises at least one sensor configured to measure the profile of the ingot using radar.

5. The direct chill casting system of claim 4, wherein the at least one sensor is arranged relative to casting equipment of the direct chill casting system such that the at least one sensor measures the profile of a rolling face of the ingot defining a width of the ingot.

6. The direct chill casting system of claim 4, wherein the at least one sensor is movable and / or actuated such that a position of the at least one sensor is adjustable.

7. The direct chill casting system of claim 4, wherein the at least one sensor comprises a plurality of sensors, wherein the plurality of sensors are arranged relative to casting equipment of the direct chill casting system such that at least one sensor measures the profile of a first rolling face of the ingot and at least one sensor measures the profile of a second rolling face of the ingot.

8. The direct chill casting system of claim 1, further comprising: a profile actuator configured to control a profile of the ingot; andPatent Application Attorney Docket #: 108050-1446983 a control system, wherein the control system is configured to generate a control response for the profile actuator based on the measured profile from the profile measuring system during casting.

9. The direct chill casting system of claim 8, wherein the profile actuator comprises a mold of the direct chill casting system, and wherein the control response controls a shape defined by the mold.

10. The direct chill casting system of claim 8, wherein the profile actuator comprises a bottom block of the direct chill casting system, and wherein the control response controls a speed of the bottom block.

11. The direct chill casting system of claim 1, wherein the ingot is a first position ingot of a plurality of ingots being simultaneously cast by the direct chill casting system, and wherein the profile measuring system is configured to measure the profile of a first rolling face of the first position ingot and a second rolling face of a last position ingot of the plurality of ingots.

12. A method of casting an ingot, the method comprising measuring a profile of the ingot using a profile measuring system while the ingot is being cast by a direct chill casting system.

13. The method of claim 12, wherein measuring the profile comprises using radar to measure the profile of the ingot.

14. The method of claim 12, further comprising controlling a profile actuator of the direct chill casting system based on the measured profile of the ingot during casting of the ingot.

15. The method of claim 14, wherein controlling the profile actuator comprises controlling at least one of a mold of the direct chill casting system, a bottom block of the direct chill casting system, or a cooling system of the direct chill casting system.Patent Application Attorney Docket #: 108050-1446983 16. A direct chill casting system comprising: an open-ended mold defining a mold cavity for receiving molten metal during casting of an ingot; a bottom block configured to initially close a lower end of the open-ended mold and to move away from the lower end during casting of the ingot; and a profile measuring system configured to measure a profile of the ingot during casting of the ingot.

17. The direct chill casting system of claim 16, further comprising a controller configured to control at least one of the open-ended mold, the bottom block, or a cooling system of the direct chill casting system based on the measured profile of the ingot during casting.

18. The direct chill casting system of claim 16, wherein the profile measuring system comprises a plurality of sensors arranged across a rolling face of the ingot and configured to measure the profile using radar.

19. The direct chill casting system of claim 18, wherein the plurality of sensors are horizontally aligned.

20. The direct chill casting system of claim 16, wherein the ingot is a first position ingot of a plurality of ingots, and wherein the profile measuring system is configured to measure the profile of a first rolling face of the first position ingot and a second rolling face of a last position ingot of the plurality of ingots.

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