Closure Plug Manipulator for Continuous Casting Flow Control
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Solution Overview
Problem
Existing continuous casting methods face challenges in achieving high-quality, reproducible results due to surface waviness in the liquid bath, which can lead to uneven solidification and increased risk of strand defects, and are complicated by the risk of caking and complex control mechanisms.
Innovation Solution
The method involves a manipulator moving a closure plug in additional degrees of freedom beyond the initial vertical movement, allowing for adjustment of the flow field in the molten metal, which reduces surface waviness and prevents caking by creating a more robust and symmetrical flow field, thereby improving the reproducibility and quality of continuous casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a float is moved back and forth in the liquid bath to reduce surface waviness, then surface waviness is reduced, but device complexity and maintenance risk increase
Solution Approach 1:
The invention extracts the float from the liquid bath and replaces it with a closure plug that remains in the pouring tube. The closure plug performs the flow field modification function without being immersed in the liquid bath, thereby eliminating the complexity of float control mechanisms and maintenance risks associated with floats.
Solution Approach 2:
The closure plug acts as an intermediary device that modifies the flow field indirectly by changing its position within the pouring tube. This mediator approach allows flow field modification without direct interaction with the liquid bath surface, avoiding the need for complex float mechanisms.
2Manufacturing precision
If the closure plug is moved only vertically to regulate bath level, then bath level control is simple, but flow field symmetry and casting quality are insufficient
Solution Approach 1:
The invention extends the closure plug movement from a single vertical dimension to multiple dimensions by allowing lateral displacement within the pouring tube. This dimensional expansion enables the closure plug to modify the flow field more effectively and achieve better flow field symmetry, thereby improving casting quality.
Solution Approach 2:
The closure plug is designed with dynamic positioning capability in multiple degrees of freedom. This dynamic movement allows the system to adaptively optimize the flow field under different operating conditions, achieving both high casting quality and operational flexibility.
3Productivity
If deposits build up on the closure plug, then flow regulation is impaired, but frequent maintenance reduces productivity
Solution Approach 1:
The invention introduces a gas injection system that uses pneumatic pressure to prevent deposits from building up on the closure plug. Gas is injected through the closure plug or around it, creating turbulent flow that prevents deposition and maintains flow regulation stability, thereby ensuring continuous productive operation without frequent maintenance interruptions.
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 simplifies the continuous casting process, reduces surface waviness, prevents caking, and ensures a more uniform solidification of the strand, leading to improved material properties and reduced risk of defects, while maintaining a constant bath level and efficient operation.
Implementation Method 1
the manipulator thus exerts a fluid-mechanical influence on the molten metal. This additional freedom of movement can open up the possibility of changing the formed flow field.
Implementation Method 2
For comparatively high-quality continuous casting, a symmetrical flow field in the liquid bath is required, among other things, which is also reflected in the waviness of the surface of the liquid bath in the mold.
Implementation Method 3
the volume flow of the molten metal through this immersion pouring tube is set and/or regulated by a closure plug in that a manipulator connected to the closure plug moves the closure plug in a first degree of freedom
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A method for continuous casting of a strand is presented. To enable reproducible, high-quality continuous casting, it is proposed that the manipulator (8), while the molten metal (3) flows from the container (2) via the immersion casting tube into the liquid bath (6) of the mold (4), particularly during strand withdrawal, moves the sealing plug (7) in at least one further degree of freedom (x, y, ϕx, ϕy, ϕz), which is different from the first degree of freedom (z), in particular along a second path of motion (11), and thus acts on the molten metal (3) in a fluid-mechanical manner to change the resulting flow field (ux,y,z,t).