Casting Level Regulation via Cyclic Roller Spacing Adjustment
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Solution Overview
Problem
Existing methods for regulating the casting level in continuous strand casting machines are unable to effectively compensate for high-frequency bulging, leading to irregularities in the steel product and reduced quality, especially at casting speeds above 2 m/min, as they lack the necessary dynamic range to offset frequencies greater than or equal to 0.6 Hz.
Innovation Solution
The method involves cyclically changing the spacing of opposing rollers in the strand guide before complete solidification to directly correct casting level variations, allowing for higher frequency oscillations to be offset, thereby improving the quality and stability of the steel product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing regulation methods are used to control casting level, then the system is simple to operate, but the dynamic range is insufficient to compensate for high-frequency bulging (frequencies >= 0.6 Hz)
Solution Approach 1:
The invention applies dynamics by making the roller spacing adjustable and variable during operation. The strand guide rollers are positioned on adjustable supports that can change their spacing dynamically in response to detected casting level variations, enabling the system to respond to high-frequency bulging (>= 0.6 Hz) that static or slowly-adjustable systems cannot handle.
Solution Approach 2:
The invention implements feedback by using detectors to continuously monitor casting level variations and using this information to automatically adjust the roller spacing. The control unit receives detector signals and actuates the roller spacing adjusters accordingly, creating a closed-loop system that compensates for bulging in real-time.
2Productivity
If casting speed is increased above 2 m/min to improve productivity, then output increases, but high-frequency bulging occurs causing product irregularities
Solution Approach 1:
The invention uses mechanical vibration by cyclically varying the roller spacing at frequencies matching the detected bulging frequency. This creates a counter-vibration effect that dampens the harmful high-frequency oscillations in the molten steel, allowing high casting speeds to be maintained without compromising product quality.
Solution Approach 2:
The invention applies parameter changes by dynamically altering the roller spacing parameter in response to detected casting level variations. The control system adjusts this physical parameter in real-time to counteract bulging effects, enabling high-speed casting while maintaining manufacturing precision.
3Reliability
If roller spacing is cyclically changed to compensate for high-frequency bulging, then casting level regulation dynamic range increases, but device complexity increases
Solution Approach 1:
The invention applies segmentation by dividing the strand guide into multiple independent roller pairs, each with its own spacing adjustment capability. This modular approach allows localized adjustments without requiring complex system-wide changes, managing device complexity while achieving the needed dynamic regulation range.
Data Source
AI summary
A method and a device for regulating a continuous casting system. The continuous casting system has a mold (1) and a strand guide (8) which is arranged downstream of the mold (1). Molten metal (3) is cast into the mold (1), in particular via an inlet device (4). The molten metal hardens on walls (1a) of the mold (1), such that a metal strand (7) with a hardened strand shell (5) and a still liquid core (6) is formed. The metal strand (7) is drawn out of the mold (1) by mutually spaced rollers (8b) of the strand guide (8), and a measurement variable is ascertained which correlates to the undulation of the casting level formed in the mold. The measurement variable is processed using at least one computing specification and is used to reduce the undulation of the casting level. In order to reduce the undulations of the casting level, the mutual spacing of opposing rollers (8b) of the strand guide is changed cyclically prior to the full hardening point (D).