Continuous Casting Plan Adjustment Using Strand Image Feedback
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Solution Overview
Problem
Current production planning systems in continuous casting plants are unable to dynamically respond to deviations during the manufacturing process, leading to increased waste, storage costs, and inefficiencies due to process-related conditions, plant malfunctions, and steel supply deviations, resulting in products that cannot be directly assigned to customer orders.
Innovation Solution
A method that compares target and actual production parameters, creates a strand replica based on actual parameters, and uses a decoupled bidirectional connection between the production and planning systems to generate a new production plan that optimizes for parameters such as scrap positions, quality predictions, and customer orders, ensuring minimal waste and reduced storage costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If production plans are created in advance using traditional planning systems, then production can proceed according to predetermined specifications, but the system cannot dynamically respond to deviations during manufacturing, leading to increased waste and storage costs
Solution Approach 1:
The patent implements dynamic production planning by continuously monitoring actual production parameters (strand casting speed, meniscus position, mold width, cooling parameters, melt temperature, casting powder thickness) and comparing them against target parameters. When deviations are detected, the system dynamically adjusts the production plan in real-time rather than following predetermined specifications, thereby reducing waste and storage costs while maintaining productivity
Solution Approach 2:
The system establishes a closed-loop feedback mechanism where actual production parameters are continuously measured and fed back to the planning system. This feedback enables the system to identify deviations from target parameters and automatically generate adjusted production plans, transforming the traditional open-loop predetermined planning into a responsive dynamic system that minimizes waste
2Loss of substance
If the system continuously monitors and dynamically adjusts production plans in real-time, then waste and storage costs are minimized, but the system complexity and computational requirements increase
Solution Approach 1:
The patent divides the continuous casting production process into discrete monitorable segments with specific target parameters (strand casting speed, meniscus position, mold width, cooling parameters, melt temperature, casting powder thickness). By segmenting the monitoring objectives into distinct measurable parameters, the system achieves comprehensive real-time monitoring without overwhelming complexity, enabling dynamic plan adjustment while managing system complexity through structured parameter breakdown
3Reliability
If production parameters deviate from target values, then actual production conditions reflect real process variations, but traditional systems cannot adapt, resulting in products that cannot be assigned to customer orders and require reprocessing or scrapping
Solution Approach 1:
The patent applies preliminary action by proactively adjusting the production plan before deviations result in defective products. When actual parameters deviate from targets, the system immediately generates adjusted production plans that account for the deviations, ensuring that subsequent products are still suitable for customer orders. This preventive approach eliminates the need for reprocessing or scrapping by addressing quality issues before they manifest in final products
Data Source
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AI summary
The present invention relates to the field of continuous casting plants in the metal-producing industry. The problem addressed by the invention is to provide a method which ensures the most cost-efficient production possible with minimum waste and reduced storage costs. The problem is solved by comparing target production parameters with actual production parameters. If the actual production parameters deviate from the target production parameters, a strand image is created on the basis of actual production parameters. The strand image comprises the strand (7) that has already been cast and not yet cut, and at least the strand (7) that arises as a result of a residual weight in the tundish and predefined parameters. With the aid of the calculated strand image, a check is carried out within the predefined production plan and, if possible, a new production plan is created. If no solution can be found from the predefined production plan, the strand image is transmitted to a production planning system (4). The production planning system (4) creates a new production plan from all available orders on the basis of a predefined optimisation criterion. The new production plan is subsequently transmitted to the production system (3).