Continuous Casting Crater End Detection via Segment Frame Bending
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Solution Overview
Problem
Existing methods for determining the crater end location of a cast metal product in continuous casting are either inaccurate or require frequent maintenance, such as displacement sensors that are difficult to detect and prone to defects, or require stopping the installation for sensor replacement.
Innovation Solution
Measuring the bending of the nearest upper segment frame in a continuous casting machine using strain gauges or extensometers to calculate the crater end location, allowing for continuous operation and minimal maintenance, with optional dual measurements for increased accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If displacement sensors are used to detect crater end location, then measurement capability is provided, but measurement precision deteriorates due to difficulty in detecting 0.1 mm displacement and sensitivity to product defects
Solution Approach 1:
The patent replaces displacement sensors with load sensors that measure force instead of small mechanical displacements. The load sensors detect changes in load on adjacent rolls to determine when the crater end is reached, avoiding the difficulty of measuring tiny 0.1 mm displacements while maintaining measurement accuracy.
2Measurement precision
If strain gauges are stuck on roll chocks for crater end detection, then measurement capability is provided, but ease of repair deteriorates because the installation must be stopped and full segments must be removed to replace sensors
Solution Approach 1:
The patent extracts the sensing function from the roll segments and places load sensors on the housing of bearings supporting the rolls. This allows sensors to be installed and replaced independently without removing entire roll segments or stopping the installation, significantly improving ease of repair and maintenance.
3Ease of repair
If load sensors are installed on roll bearings to detect crater end, then ease of repair is improved, but measurement precision deteriorates due to indirect measurement through load difference calculation
Solution Approach 1:
The patent uses load sensors to continuously monitor the load on adjacent rolls and calculates the load difference to determine when the crater end is reached. This feedback mechanism provides accurate real-time detection of the solidification front position while maintaining ease of sensor replacement.
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
Accurately determines the crater end location, enabling precise monitoring of casting speed and application of dynamic soft reduction, thereby increasing productivity and reducing maintenance needs.
Implementation Method 1
At least measuring the bending of the nearest upper segment frame of the estimated location Pest
Data Source
AI summary
A method to determine the crater end location of a cast metal product during its casting, the crater end location being the location at which the cast metal product becomes fully solidified. A continuous casting method and a continuous casting machine are also provided.