Casting Cooling Feedback for Uniform Rolled Product Temperature
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Solution Overview
Problem
Combined casting/rolling installations face challenges in producing rolled products with high quality, particularly in achieving homogeneous material and surface properties, due to variations in temperature profiles and other properties during the casting and rolling process.
Innovation Solution
A control device with a measuring unit and controller is used to detect temperature profiles and other properties of rolled products, generating control signals to adjust cooling parameters of the casting machine, thereby influencing the temperature profile and ultimately the quality of the rolled product through an automated feedback loop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual operation and control of casting parameters is used, then operational flexibility is maintained, but rolled-product quality consistency deteriorates due to temperature profile variations
Solution Approach 1:
The patent implements a feedback control system where a measuring unit detects the actual temperature profile of the rolled product, and the controller adjusts casting parameters based on this feedback to maintain temperature profile within target range, ensuring consistent rolled-product quality
Solution Approach 2:
The patent replaces manual mechanical control of casting parameters with an automated control system that uses measuring units to detect temperature profiles and controllers to automatically adjust casting parameters, eliminating human error and improving consistency
2Manufacturing precision
If extensive expertise and complex equipment are used to maintain quality, then rolled-product quality consistency improves, but operational simplicity deteriorates
Solution Approach 1:
The control system performs self-adjustment by automatically detecting temperature profiles and modifying casting parameters without requiring operator intervention, making the system easy to operate while maintaining high quality consistency
Solution Approach 2:
The automated feedback loop continuously monitors temperature profiles and adjusts casting parameters in real-time, eliminating the need for extensive operator expertise while maintaining consistent rolled-product quality
3Stability of the object's composition
If casting parameters are not adjusted based on real-time feedback, then operational simplicity is maintained, but temperature profile homogeneity deteriorates
Solution Approach 1:
The measuring unit detects the actual temperature profile and provides feedback to the controller, which adjusts casting parameters to maintain temperature homogeneity within the rolled product
Solution Approach 2:
The controller modifies casting parameters such as casting speed, cooling water flow rate, and mold opening based on detected temperature profile variations to maintain optimal temperature homogeneity in the rolled product
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 method enables the production of rolled products with consistent high quality without requiring extensive expertise or equipment, maintaining high quality levels by automatically adjusting casting parameters based on real-time property feedback.
Implementation Method 1
a rolled-product property, which in this case is a temperature profile of the rolled product (in the width direction thereof), is detected by the measuring unit
Implementation Method 2
The casting machine uses the control signal to set a casting parameter. The rolled-product property that is detected by the measuring unit is a temperature profile of the rolled product (in the width direction thereof) and the casting parameter that is set by the casting machine using the control signal is a cooling parameter of the casting machine
Data Source
AI summary
A method for operating a combined casting/rolling installation: A casting machine (4) of the combined installation (2) produces a cast product (40) and a rolling mill (6, 8) of the installation (2) produces a rolled product (42a, 42b) from the cast product (40). The installation (2) has a control device (12) with a measuring unit (14) and a controller (16). The measuring unit (14) detects a rolled-product property, generates a measurement signal dependent on that property and transmits the measurement signal to the controller (16), and the controller (16) uses the measurement signal to generate a control signal for the casting machine (4) based on a control algorithm and transmits the control signal to the casting machine (4) which uses the control signal to set a casting parameter. The detected rolled-product property is a temperature profile of the rolled product (42a, 42b) in the width direction thereof and the casting parameter that is set by the casting machine (4) using the control signal is a cooling parameter of the casting machine (4).