Continuous Casting Mold Temperature Sensor Data Correction
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Solution Overview
Problem
In continuous casting, temperature sensors installed at varying distances from the hot side of the mold wall distort the temperature image, making interpretation difficult and leading to potential misinterpretations, as it is challenging to maintain a uniform distance due to structural conditions and sensor installation limitations, and direct temperature measurement on the hot side is not feasible due to safety concerns.
Innovation Solution
A method where the evaluation device calculates a fictitious uniform temperature gradient based on the casting speed and liquid level, converting measured temperature values into calculated temperature values using the formula T' = T + k ⋅ d' - d, where T' is the calculated temperature, T is the measured temperature, k is the temperature gradient, d' is the fictitious distance, and d is the actual installation distance, allowing for accurate temperature evaluation independent of sensor installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If temperature sensors are installed at varying distances from the hot side of the mold wall due to structural conditions and installation limitations, then the sensors can be positioned in difficult-to-reach areas, but the temperature measurements become distorted and difficult to interpret
Solution Approach 1:
The patent changes the parameter of distance by introducing a fictitious uniform distance d' for all sensors. The evaluation device calculates a temperature gradient k and converts measured temperatures T at actual distances d into calculated temperatures T' at the fictitious distance d', thereby standardizing the measurement reference point and eliminating the distorting effect of varying installation distances
Solution Approach 2:
The patent introduces a fictitious distance d' as an intermediary reference point. This fictitious distance serves as a common reference plane from which all temperature measurements are standardized, allowing sensors at different actual distances to provide comparable temperature data as if they were all located at the same position
2Measurement precision
If temperature sensors are placed directly at the hot side of the mold wall to obtain accurate temperature measurements, then the temperature readings would be most accurate, but the sensors would be destroyed quickly due to high temperatures and safety concerns
Solution Approach 1:
The patent creates a virtual copy of the temperature field at the hot side by calculating temperatures T' at a fictitious distance d' that represents the hot side location. Instead of placing physical sensors at the dangerous hot side position, the system computes equivalent temperature values through mathematical transformation of measurements taken at safe distances
Solution Approach 2:
The fictitious distance d' acts as an intermediary that represents the hot side location without requiring physical presence there. The evaluation device uses this intermediary reference to calculate what the temperature would be at the hot side based on measurements taken at safe distances, thereby obtaining accurate hot side temperatures without exposing sensors to destructive conditions
3Measurement precision
If a uniform distance between temperature sensors and the hot side is maintained to standardize measurements, then temperature comparisons become reliable, but installation becomes difficult due to mold wall shape and sensor mounting constraints
Solution Approach 1:
The patent transforms the distance parameter from a fixed physical constraint to a flexible computational variable. By allowing actual distances d to vary while calculating equivalent temperatures at a uniform fictitious distance d', the system achieves measurement standardization without imposing rigid installation requirements, thereby resolving the conflict between measurement comparability and installation ease
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 high-quality temperature image evaluation by standardizing temperature measurements, reducing misinterpretation risks, and allowing calculation of temperatures directly at the mold wall to metal strand interface, providing optimal insight into the continuous casting process.
Implementation Method 1
a respective temperature sensor is arranged in the mold wall at a respective installation distance from a hot side of the mold wall facing the cast metal strand, which provides a respective measured temperature value
Implementation Method 2
for the respective temperature sensor, a respective temperature gradient in the thickness direction is determined
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
Liquid metal (3) is poured from above into a mold cavity (1) of a continuous casting mold, which is bounded by at least one mold wall (2). The liquid metal forms a casting surface (15) within the mold cavity (1). A partially solidified metal strand (4) is drawn from the mold cavity (1) at a pouring velocity (v) from below. Temperature sensors (10) are arranged in the mold wall (2) at installation distances (d) from a hot side (7) of the mold wall (4) facing the cast metal strand (4). These sensors provide measured temperature values (T). The measured temperature values (T) are fed to an evaluation unit (12), which converts them into calculated temperature values (T') according to the relationship T' = T + k · (d'-d).Here, T' is the calculated temperature value (T'), T is the measured temperature value (T), k is the temperature gradient (k) in the thickness direction, d' is a uniform fictitious distance (d') from the hot side (7) of the mold wall (2), and d is the installation distance (d). The temperature gradients (k) are determined by the evaluation unit (12) depending on the pouring speed (v) and/or the pouring level (15).