Casting Plate Protrusion for Automated Stroke Control
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Solution Overview
Problem
Existing continuous molten metal casting systems require bulky, heavy, and costly double-stroke jacks for controlling the movement of casting tubes between casting and sealing positions, necessitating manual intervention and increased safety risks during emergency stops.
Innovation Solution
A device with a casting plate passage detector and a pusher limit switch that automatically determines the stroke length, allowing the pusher to move the casting plate to either the casting or sealing position based on the presence of a replacement plate, enabling remote and rapid operation without the need for manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If double-stroke jacks are used to control casting tube movement between casting and sealing positions, then the system can achieve selective positioning capability, but the device becomes bulky, heavy, and costly
Solution Approach 1:
The casting plate is segmented into two distinct functional surfaces: a casting channel face for normal operation and a sealing face for emergency closure. This segmentation allows a single-stroke jack to push the plate into different positions depending on which face needs to engage with the detector, eliminating the need for complex double-stroke mechanisms while maintaining selective positioning capability
Solution Approach 2:
A detector-engaging protrusion is introduced as an intermediary element on the casting plate that interacts with a detector on the pusher. This intermediary mechanism provides feedback about the plate's position and enables automatic control of the jack stroke, replacing the need for bulky double-stroke jacks with a simpler single-stroke jack controlled by an automated detection system
2Adaptability or versatility
If double-stroke jacks are used for selective positioning, then casting and sealing positions can be controlled, but the system requires bulky and costly components
Solution Approach 1:
By segmenting the casting plate into two functional faces (casting channel face and sealing face) and using a detector-engaging protrusion, the system can control positioning with a lighter single-stroke jack. The detector on the pusher reads the protrusion position to automatically determine whether to perform a short or long stroke, eliminating the need for heavy double-stroke jack mechanisms
Solution Approach 2:
The patent replaces the mechanical complexity of double-stroke jacks with an automated detection and control system. A detector on the pusher reads the position of a protrusion on the casting plate and automatically controls the jack stroke length, substituting mechanical complexity with sensor-based control and reducing overall system weight
3Ease of operation
If manual intervention is required for emergency stops, then operator control is maintained, but safety risks and response times are adversely affected
Solution Approach 1:
The system performs self-service through automated detection and control. When the detector on the pusher reads the position of the protrusion on the casting plate, it automatically determines the required stroke length and controls the jack accordingly. This eliminates the need for manual intervention during emergency stops, improving both safety and response time while maintaining operational reliability
4Adaptability or versatility
If manual handling of blank plates is required, then flexibility is maintained, but operator error risk increases and response times decrease
Solution Approach 1:
The automated detection system performs self-service by automatically determining the required jack stroke based on the detector reading of the protrusion position. This eliminates manual handling of blank plates and associated errors, improving response time and productivity while maintaining operational flexibility through the automated control mechanism
Data Source
AI summary
Casting plates constructed for facing the casting orifice of a metallurgical vessel are provided with a metallic casing. The casting plates and metallic casing are provided with a protrusion configured to interact with a detector. The casing has a main surface with an opening, and two substantially longitudinal bearing surfaces. The protrusion extends from the casing in a direction substantially parallel to the longitudinal bearing surfaces. The protrusion is formed by a ramp having an inclined portion.