Caster Mold Profile Measurement Using Laser Scanning

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Solution Overview

Problem

Conventional methods for characterizing the integrity and measuring the profiles of caster molds are inefficient, leading to downtime and difficulties in maintaining dimensional tolerances, especially for thin slab caster molds with parabolic profiles, due to manual and offline measurements using contact sensors.

Innovation Solution

A scanning device with a laser, optics, scanner, photodetector, and receiver electronics is used, attached to a fixture for positioning, to measure distances on internal surfaces of the caster mold, comparing these distances to reference values to characterize and measure the profile, allowing for real-time and accurate monitoring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual and offline measurements using contact sensors are used, then measurement accuracy can be achieved, but downtime increases and productivity decreases

Engineering Contradiction:

Improvemeasurement accuracyVSAvoiddowntime

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces manual contact sensors with a scanning laser range finder that uses optical fields to measure mold profile. The laser scanning device projects laser beams across the mold interior surfaces and detects reflected light to calculate distances, eliminating the need for physical contact with the mold. This substitution enables non-contact measurement during operational periods, significantly reducing downtime while maintaining measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The scanning laser range finder enables continuous monitoring of the caster mold profile without interrupting the casting process. The device can perform multiple scans during operational periods to track wear and dimensional changes over time, providing continuous data without the stop-start nature of manual measurement. This continuous action maintains productivity while ensuring ongoing measurement accuracy.

Inventive Principle:

Principle #20Continuity of useful action

2Measurement precision

If manual and offline measurements are used, then measurement accuracy can be achieved, but the complexity of maintaining dimensional tolerances increases

Engineering Contradiction:

Improvemeasurement accuracyVSAvoidcomplexity of maintaining dimensional tolerances

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The scanning laser range finder provides systematic feedback on mold dimensional changes by comparing current measurements against reference profiles. The device captures comprehensive 3D data of the mold interior surfaces and processes this information to identify deviations from acceptable tolerances. This feedback mechanism simplifies maintenance complexity by providing clear, quantifiable data on when and where dimensional changes occur, enabling proactive maintenance decisions.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If contact sensors are used for measurement, then measurement accuracy is achieved, but ease of operation decreases due to manual intervention requirements

Engineering Contradiction:

Improvemeasurement accuracyVSAvoidease of operation

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The scanning laser range finder is designed to perform measurements autonomously without requiring skilled operators or manual intervention. The device automatically positions itself, projects laser beams, detects reflected light, and processes measurements to generate reports. This self-service capability maintains measurement accuracy while dramatically improving ease of operation, allowing any staff member to conduct measurements with minimal training.

Inventive Principle:

Principle #25Self-service

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

This approach significantly reduces downtime and improves measurement accuracy, enabling continuous monitoring of caster mold integrity and detecting wear, cracks, or changes in profile, thus enhancing operational safety and productivity.

Implementation Method 1

a laser, optics, a scanner, a photodetector, and receiver electronics to measure distances from a position of the scanning device to a plurality of points on internal surfaces of the caster mold

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS9435889B2Caster mold measurements using a scanning range finder

Publication Date: 2016.09.06 VESUVIUS PROCESS METRIX SAS(FR)

AI summary

Apparatuses, methods, and systems are disclosed for the characterization of the integrity and profile measurement of a caster mold by use of a scanning device, a positioning fixture, and a data reduction device connected to the scanning device, the data reduction device being configured to characterize the integrity and to measure the profile of the caster mold by comparing scanned distances to reference distance values.