Continuous Casting Powder Feed Control via Bath Level and Temperature
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Solution Overview
Problem
Existing control systems for continuous casting plants are inefficient in accurately regulating the casting powder feed due to various influencing variables, leading to incorrect feeding and increased complexity and costs.
Innovation Solution
A system utilizing a first measuring device to determine the bath level and a second measuring device to measure the temperature of the casting powder, with a computer unit evaluating both signals to precisely control the casting powder feed, optimizing the timing and quantity based on steel type and casting speed, and using an optical image evaluation unit with a thermal imaging camera and deflection device for non-contact temperature determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If automated casting powder supply devices are used with fixed time intervals, then the feeding process is simplified, but the control accuracy deteriorates due to many influencing variables changing consumption through burn-off and entrainment
Solution Approach 1:
The patent implements feedback control by continuously measuring the actual casting powder consumption through burn-off and entrainment variables, comparing it with the target consumption, and adjusting the feeding rate accordingly. This closed-loop system maintains control accuracy while managing the complexity of multiple influencing variables.
Solution Approach 2:
The system dynamically changes feeding parameters (rate, timing, amount) based on real-time measurements of burn-off, entrainment, and other influencing variables. This allows the control system to adapt to changing conditions and maintain precision without requiring complete simplification of the feeding process.
2Measurement precision
If control arrangements with multiple measuring devices are used, then the control accuracy is improved, but the device complexity and costs increase
Solution Approach 1:
The patent employs measuring devices that serve multiple functions - for example, thermal imaging cameras that simultaneously measure temperature distribution, detect powder layer thickness, and monitor burn-off rates. This multi-functionality reduces the total number of devices needed while maintaining high control accuracy.
Solution Approach 2:
The system uses intermediate processing units that integrate data from multiple measuring devices and translate it into control signals. This intermediary layer simplifies the overall control structure by centralizing the complexity in a dedicated processing unit rather than distributing it across multiple independent control systems.
3Measurement precision
If thermal radiation measurement is used to determine casting powder slag thickness, then the measurement capability is enhanced, but the system becomes more complex and costly
Solution Approach 1:
The patent replaces direct physical contact measurement methods with thermal radiation-based optical measurement. Thermal imaging cameras detect infrared radiation from the casting powder slag to determine thickness and temperature distribution without mechanical contact, thereby enhancing measurement capability while avoiding the complexity of mechanical probe systems.
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 precise and accurate control of the casting powder feed, reducing error tolerances and optimizing the feeding process by adjusting the flow rate and timing according to real-time temperature and level measurements, thereby improving the overall efficiency and reliability of the continuous casting process.
Implementation Method 1
a second measuring device for determining the temperature of the casting powder on the surface of the bath level in the continuous casting mold
Data Source
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AI summary
The subject of the invention is an arrangement for controlling the casting powder feed of a continuous casting plant, comprising a first measuring device for determining the height of a bath level (12) in a continuous casting mold (14) and generating a corresponding first signal, a second measuring device (16) for determining the temperature of the casting powder (18) on the surface of the bath level (12) in the continuous casting mold (14) and generating a corresponding second signal, and a computer unit (36) for evaluating the first signal from the first measuring device (10) and the second signal from the second measuring device (16), by means of which a casting powder feed device (28) can be controlled. The invention further relates to a corresponding method.