Casting Gap Measurement With Tie Rod Elongation Compensation
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Solution Overview
Problem
Existing methods for controlling the casting gap in continuous casting processes fail to accurately account for the elongation of tie rods due to their elastic bending, leading to inaccuracies in gap regulation and potential adverse effects on the control loop's time response.
Innovation Solution
A measuring device using a displacement sensor and a magnetostrictive effect to measure the travel distance of a piston in a hydraulic segment cylinder, incorporating a force-free reference rod to determine the elongation of the tie rod, allowing for precise calculation of tensile force and compensation for elongation in the control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If tie rods are designed to be slender to allow for elastic bending and misalignment adjustment, then adaptability is improved, but tensile stiffness deteriorates leading to considerable longitudinal strain
Solution Approach 1:
The measurement system is segmented into two independent measurement paths: one measuring piston travel distance and another measuring tie rod elongation. This segmentation allows each measurement to be optimized for its specific function without interference from the other, resolving the contradiction between adaptability and stiffness by measuring both effects separately.
Solution Approach 2:
A force-free reference rod is introduced as an intermediary element that transmits only the casting gap position without being subjected to tensile forces. This reference rod serves as a mediator between the piston and the measurement system, allowing accurate measurement of piston travel independent of tie rod elastic deformation.
2Ease of operation
If displacement measuring device is attached to hydraulic cylinder to detect travel distance, then ease of operation is improved, but measurement precision deteriorates because it does not detect tie rod extension
Solution Approach 1:
The measurement system is divided into two independent measurement paths: one measuring piston travel distance and another measuring tie rod elongation. This segmentation allows each measurement to be optimized for its specific function without interference from the other, resolving the contradiction between ease of operation and measurement precision by measuring both effects separately.
Solution Approach 2:
The system implements feedback by continuously measuring both piston position and tie rod elongation, then using this combined information to calculate the actual casting gap position. This feedback mechanism compensates for the limitations of simple displacement sensors by incorporating real-time data about tie rod elastic deformation.
3Device complexity
If casting gap control is based on hydraulic cylinder travel distance measurement, then device complexity is reduced, but measurement precision deteriorates due to unaccounted tie rod expansion
Solution Approach 1:
The measurement system is divided into two independent measurement paths: one measuring piston travel distance and another measuring tie rod elongation. This segmentation allows each measurement to be optimized for its specific function without interference from the other, resolving the contradiction between device complexity and measurement precision by measuring both effects separately.
Solution Approach 2:
The system performs preliminary measurement of tie rod elongation independently before using this information to correct the casting gap position calculation. By measuring the tie rod extension in advance and separately, the system can compensate for its effect on the overall measurement without adding complex real-time correction mechanisms.
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 accurate determination of the casting gap by disregarding piston travel and accounting for tie rod elongation, improving control loop responsiveness and precision in gap regulation.
Implementation Method 1
The operation of the displacement sensor is based on the magnetostrictive effect induced in the measuring rod
Data Source
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AI summary
The invention is in the field of continuous casting technology and describes a device and a method for measuring and compensating force-induced tie rod deformations in a continuous casting segment. The measuring device detects the travel of a piston in a hydraulic segment cylinder of a continuous casting segment, as well as the tensile force of a tie rod connecting an inner and outer frame. Furthermore, a method for controlling a casting gap and a control device are described. The operation of the displacement sensor is based on the magnetostrictive effect induced in the measuring rod, wherein the magnetostrictive effect is caused by at least one first magnet arrangement positioned at a specific location on this measuring rod. A force-free reference rod runs parallel to the tie rod, with a second magnet arrangement attached to one end of the reference rod.The displacement sensor determines the distance between the first magnet array and a reference plane, as well as the distance (x2) between the second magnet array and the reference plane. This allows for the determination of tie rod elongation or the control of a casting gap.