Continuous Casting Steel Cooling Water Spray Control
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Solution Overview
Problem
Existing continuous casting methods face challenges in maintaining the solidification completion position of steel cast slabs when the drawing speed is changed, leading to potential changes in the solidification completion position and increased center segregation, which affects the quality of steel products.
Innovation Solution
A method that adjusts the cooling water spray amount based on the change in drawing speed to maintain the solidification completion position at a predetermined target, using specific formulas to calculate the optimal cooling water spray amount during the transition period, ensuring the solidification completion position remains stable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the drawing speed of the cast slab is changed to restore target speed after ladle exchange or temperature abnormality detection, then the productivity is improved, but the solidification completion position changes leading to center segregation
Solution Approach 1:
The patent applies preliminary action by predicting the solidification completion position before actually casting the steel slab. A response model is prepared in advance that expresses the relationship between casting speed changes and the moving response of the solidification completion position. This allows the system to pre-calculate the appropriate cooling water spray amount needed to compensate for speed changes, ensuring the solidification completion position remains accurate even when drawing speed is adjusted for productivity reasons.
Solution Approach 2:
The patent utilizes parameter changes by dynamically adjusting the cooling water spray amount based on the predicted solidification completion position. When drawing speed changes occur, the system modifies the cooling water spray parameters (amount and timing) to compensate for the expected shift in solidification completion position. This parameter adjustment ensures that the solidification completion position is maintained at the target location despite changes in casting speed, thereby preventing center segregation while allowing productivity improvements.
2Manufacturing precision
If the solidification completion position is constantly monitored using ultrasonic sensor to prepare response model, then the manufacturing precision is improved, but the time and effort for model preparation increases
Solution Approach 1:
The patent applies the copying principle by using measured data from actual solidification completion positions to create a response model that can be reused for prediction. Instead of continuously measuring during each casting operation, the system collects data during initial model preparation, creates a mathematical representation (copy) of the relationship between casting parameters and solidification position, and then uses this model for rapid predictions during subsequent operations. This eliminates the need for time-consuming real-time measurements while maintaining precision.
Solution Approach 2:
The patent applies preliminary action by preparing the response model in advance before actual casting operations begin. The model preparation phase involves collecting data and establishing the mathematical relationship between casting speed changes and solidification completion position movement. Once prepared, this model enables rapid predictions without requiring time-consuming measurements during each casting operation, thus reducing operational time while maintaining control precision.
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 effectively prevents large changes in the solidification completion position when the drawing speed is altered, thereby reducing center segregation and improving the quality of steel products by maintaining the solidification completion position within the soft rolling reduction zone.
Implementation Method 1
spraying cooling water toward the cast slab
Implementation Method 2
solidifying the molten steel while the filling to form a cast slab
Data Source
AI summary
Provided is a continuous casting method of steel that prevents a solidification completion position from being changed even when a drawing speed V of a cast slab is changed. The method includes drawing a cast slab by setting a drawing speed V0 while spraying cooling water to the cast slab at a cooling water spray amount W0 [kg/ton-cast slab]. Then, changing the drawing speed to the speed V1 while spraying cooling water to the cast slab at a cooling water spray amount W1 [kg/ton-cast slab]. The method further includes spraying cooling water to the cast slab at a cooling water spray amount Wt [kg/ton-cast slab] during a period of time t that is obtained by dividing a target length Lt by the drawing speed V0. The water spray amount Wt satisfying either formula (1): Wt<W1 under a condition of V1<V0, or formula (2): Wt>W1 under a condition of V1>V0.