Continuous Casting Mold Flow Control Using Real-Time Steel Flow Index
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Solution Overview
Problem
Current methods for controlling molten steel flow in continuous casting machines fail to accurately estimate and control the molten steel flow index, which is crucial for minimizing defects caused by impurities like bubbles and inclusions, leading to suboptimal casting quality.
Innovation Solution
A real-time control method that estimates the molten steel flow state using operation conditions and temperature data, calculates a molten steel flow index indicating impurity mixing, and adjusts operation conditions such as casting speed, magnetic flux density, and nozzle submerging depth to maintain the flow index within appropriate ranges, including stirred flow velocity and turbulence energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic field is applied to molten steel in mold to control flow, then quality of castings is stabilized, but unexpected variation in operation makes it difficult to fully control the flow
Solution Approach 1:
The patent employs feedback control by measuring copper plate temperature in the mold and using this data to correct and adjust the molten steel flow control. The temperature measurements provide real-time feedback about the solidification state, which is then used to dynamically adjust the magnetic field application or other control parameters to compensate for operational variations and maintain precise flow control throughout the casting process.
2Object-affected harmful factors
If molten steel flow velocity at solidification interface is increased to reduce impurity trapping, then defects are reduced, but control precision of flow velocity is insufficient with conventional methods
Solution Approach 1:
The patent replaces conventional mechanical flow control methods with electromagnetic field-based control. By applying magnetic fields to the molten steel, the system can precisely control flow velocity without mechanical contact, enabling finer adjustment and more precise control of the molten steel flow at the solidification interface, thereby achieving better control over impurity trapping while maintaining manufacturing precision.
3Object-affected harmful factors
If geometric relation control of submerged entry nozzle is used to control flow velocity, then low-speed casting defects are reduced, but variation in operation conditions causes molten steel flow velocity to fall outside appropriate range
Solution Approach 1:
The patent transitions from static geometric control of the submerged entry nozzle to dynamic control using magnetic fields and real-time temperature feedback. This dynamic approach allows the system to adapt to varying operation conditions by continuously adjusting the magnetic field strength and duration based on measured temperature data, maintaining optimal flow velocity control across different casting speeds and operational scenarios rather than relying on fixed geometric relationships.
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 enables the production of high-quality castings by effectively controlling the molten steel flow index, reducing defects and improving casting quality by dynamically adjusting operation conditions based on real-time data.
Implementation Method 1
a technique controls a position of a discharge port and a discharge angle of the submerged entry nozzle relative to a position at which the moving magnetic field is applied, within appropriate ranges, when continuous casting is performed while a moving magnetic field is applied so that a braking force is applied to a discharge flow of molten steel
Implementation Method 2
a moving magnetic field is applied so that a braking force is applied to a discharge flow of molten steel
Implementation Method 3
a result of measurement of the temperature of molten steel with a temperature measuring element embedded in a mold copper plate
Data Source
AI summary
A control method for a continuous casting machine, includes: estimating, by on-line real-time system, a flow state of molten steel in a mold by using an operation condition of a continuous casting machine and temperature data on the molten steel in the mold; calculating, by on-line real-time system, a molten steel flow index based on the estimated flow state of the molten steel, the molten steel flow index being a factor of mixing of an impurity into a casting inside the mold; and controlling the operation condition of the continuous casting machine such that the calculated molten steel flow index is within an appropriate range.