Cast-Piece Solidification Measurement With Dynamic Sensor Gap Control
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Solution Overview
Problem
Existing solidification position measurement methods using electromagnetic ultrasonic sensors face challenges such as lift-off fluctuations due to cast-piece thickness variations, leading to sensor damage, decreased sensitivity, and manual analysis requirements, making continuous and automatic measurement difficult.
Innovation Solution
A solidification position measuring apparatus with an electromagnetic ultrasonic sensor, a sensor lifting and lowering unit, a gap measuring unit, and a drive control unit to adjust the gap between the sensor and the cast-piece, using a Halbach array magnet and chirp signal processing for improved sensitivity and automatic measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electromagnetic ultrasonic sensor is used for solidification position measurement, then measurement capability is provided, but lift-off fluctuation causes sensor damage and sensitivity loss
Solution Approach 1:
The sensor lifting and lowering unit dynamically adjusts the gap between the electromagnetic ultrasonic sensor and the cast-piece surface in real-time during measurement operations, allowing the system to adapt to thickness fluctuations and maintain optimal measurement conditions without sensor contact or damage
Solution Approach 2:
The gap measuring unit continuously monitors the distance between the sensor and cast-piece surface, providing feedback to the drive control unit which then actuates the sensor lifting and lowering unit to maintain the gap within the predetermined safe range, preventing both contact damage and sensitivity loss
2Device complexity
If fixed gap measurement is used, then device complexity is reduced, but measurement accuracy decreases due to thickness variation
Solution Approach 1:
The system replaces fixed mechanical positioning with a combination of gap measuring unit (likely optical or electromagnetic non-contact measurement) and automated lifting/lowering mechanism, substituting static mechanical arrangement with dynamic measurement-compensated positioning to maintain accuracy despite thickness variations
3Measurement precision
If manual analysis is performed, then sensitivity issues can be addressed, but productivity decreases
Solution Approach 1:
The drive control unit automatically processes the gap measurement data and controls the sensor positioning without requiring manual intervention, enabling the system to self-regulate and maintain optimal measurement conditions continuously, thereby achieving both high accuracy and productivity through automated operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous and automatic measurement of the solidification position by preventing sensor damage and sensitivity loss, improving signal-to-noise ratio, and allowing real-time quality management and manufacturing adjustments.
Implementation Method 1
there is a method of directly measuring the solidification position using an electromagnetic ultrasonic sensor
Implementation Method 2
a solidification position shape can be calculated from the detection/calibration of solidification and non-solidification and a longitudinal wave propagation time using the transverse ultrasonic wave and the longitudinal ultrasonic wave
Implementation Method 3
the gap measuring unit is configured to shoot water to a measurement target, propagate an ultrasonic wave in the shot water, and measure a distance from ultrasonic wave generating unit to the measurement target based on a propagation time of a reflection signal of the ultrasonic wave
Implementation Method 4
propagate an ultrasonic wave in the shot water, and measure a distance from ultrasonic wave generating unit to the measurement target based on a propagation time
Implementation Method 5
using a Halbach array magnet and chirp signal processing for improved sensitivity
Implementation Method 6
using a Halbach array magnet and chirp signal processing for improved sensitivity and automatic measurement
Data Source
AI summary
A solidification position measuring apparatus for measuring a solidification position of a cast-piece includes: an electromagnetic acoustic transducer installed outside the cast-piece; a sensor lifting and lowering unit configured to adjust a gap between the cast-piece and the electromagnetic acoustic transducer; a gap measuring unit configured to measure the gap between the cast-piece and the electromagnetic acoustic transducer; a computing unit configured to estimate the solidification position in the cast-piece from an output of the electromagnetic acoustic transducer; and a drive control unit configured to drive and control the sensor lifting and lowering unit and the gap measuring unit. The drive control unit is configured to control a position of the electromagnetic ultrasonic sensor by the sensor lifting and lowering unit based on the gap measured by the gap measuring unit.