Dynamic Torch Flow Control for Non-Rectangular Continuous Casting Strand Cutting
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Solution Overview
Problem
Conventional oxycutting systems for continuous castings with non-rectangular or non-square cross-sections, such as circular or elliptical shapes, suffer from high fluid fuel consumption, imprecision, and noise, especially when cutting sections with varying thicknesses.
Innovation Solution
A system and method that dynamically adjust the flowrate of cutting and heating fluids, as well as the speed and position of the cutting torch, based on the specific thickness of each subsection of the cross-section, to optimize fluid usage and cutting precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If constant flowrate of cutting fluid is used during the whole cutting step, then the cutting process is simple to control, but fluid consumption is high and does not adapt to varying thickness sections
Solution Approach 1:
The patent applies dynamics by transitioning from constant flowrate to variable flowrate control. The cutting fluid flowrate is dynamically adjusted based on the real-time thickness of the casting section being cut. When the torch detects thinner sections, it automatically reduces flowrate; when detecting thicker sections, it increases flowrate. This dynamic adaptation optimizes fluid consumption while maintaining cutting effectiveness across varying thicknesses.
Solution Approach 2:
The patent changes the parameter of cutting fluid flowrate from a constant value to a variable value that depends on section thickness. The system monitors thickness in real-time and modifies the flowrate parameter accordingly. This parameter change allows the same cutting system to efficiently handle sections with different thicknesses without waste, as the flowrate is precisely matched to the actual material being cut.
2Stability of the object's composition
If constant flowrate of heating fluid is used, then the heating process is stable, but it does not optimize energy usage for sections of different thicknesses
Solution Approach 1:
The heating fluid flowrate is made dynamic rather than constant. The system continuously monitors the thickness of the casting section and adjusts the heating fluid flowrate in real-time. For thinner sections, the flowrate is reduced to avoid excessive energy consumption and overheating. For thicker sections, the flowrate is increased to ensure adequate heating. This dynamic control maintains heating stability while optimizing energy usage.
Solution Approach 2:
The heating fluid flowrate parameter is changed from a fixed constant to a variable parameter that responds to section thickness variations. The control system modifies this parameter based on feedback from thickness measurements, ensuring that energy input is proportional to the actual heating requirements of each section, thereby reducing overall energy consumption while maintaining process stability.
3Manufacturing precision
If high flowrate of cutting fluid is used to ensure adequate cutting, then cutting precision is maintained, but noise level increases and fluid waste occurs in thinner sections
Solution Approach 1:
The cutting fluid flowrate is changed from a high constant value to a variable value that adapts to section thickness. The system reduces flowrate when cutting thinner sections, which directly lowers noise generation while still providing sufficient cooling and flushing for precise cutting. For thicker sections, the flowrate is maintained at higher levels to ensure cutting precision. This parameter adaptation eliminates the need to use high flowrate universally, reducing noise and fluid waste without sacrificing precision where needed.
4Manufacturing precision
If torch is handled at variable speed in X-direction, then cutting quality is improved for different thicknesses, but control complexity increases
Solution Approach 1:
The torch handling speed is changed from a constant value to a variable parameter that depends on section thickness. The control system adjusts the torch speed in real-time based on feedback from thickness measurements. For thinner sections, the torch moves faster to reduce processing time and heat input. For thicker sections, the torch moves slower to ensure adequate heating and cutting quality. This parameter variation improves cutting quality across different thicknesses while the control complexity is managed through automated feedback control.
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 reduces fluid consumption, improves cutting quality, and decreases noise by tailoring the cutting process to the varying thicknesses of the casting, resulting in more efficient and precise cuts with minimal post-processing requirements.
Implementation Method 1
a torch suitable to generate at first a heating flame locally raising the temperature of the continuous casting strand to be cut to at least 1000°C and fed by a heating fluid, such as for example a gas mixture (for example methane and oxygen)
Implementation Method 2
a cutting flame is also used for cutting, fed with pure oxygen at a steady pressure and flowrate
Data Source
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AI summary
A method and a system for cutting a strand (1D) of a continuous casting (1), wherein the cross-section of said casting has a plurality of sections having different thicknesses, said cross-section being preferably circular or elliptical or H-shaped, comprising the following steps: - providing at least one cutting and heating device (3) in correspondence with said strand to be cut (1D), - handling said cutting and heating device (3) in a plurality of different cutting and heating working positions (P0-P20) of said strand (1D) to be cut, - feeding to the cutting and heating device (3): a first fluid for heating the strand (1D) of continuous casting to be cut and a second fluid for cutting said casting strand (1D); wherein the flowrate of said first heating fluid and/or of said second cutting fluid fed to said cutting and heating device (3) changes while said strand (1D) is being heated and/or cut; characterized in that: - the cross-section of the strand (1D) of the continuous casting (1) to be cut is divided into a plurality of subsections (Z1-Z20) having different thicknesses (S1-S19), - each of said subsections (Z1-Z20) is associated to a predetermined flowrate of the second cutting fluid and/or of the first heating fluid to be fed to said cutting and heating device (3), - the position of the cutting and heating device (3) during cutting and/or heating compared to said subsections (Zl-Z20) into which the cross-section of the casting strand to be cut has been divided is detected, - depending on the detected position of the cutting and heating device (3), the flowrate of the second cutting fluid and/or of the first heating fluid fed to the cutting and heating device (3) is adjusted according to the flowrate values associated to the subsection (Z1-Z20) of the cross-section where the cutting and heating device 3 is situated.