Electromagnetic Brake System for Slab Casting Flow Control
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Solution Overview
Problem
Existing electromagnetic brake systems for metal-making processes do not provide optimal fluid flow control of molten metal near the meniscus along the entire width of the mould, leading to defects such as slag entrainment and non-metallic inclusions.
Innovation Solution
An electromagnetic brake system with a magnetic core structure comprising upper and lower decoupled magnetic core sections, each with multiple teeth and coils, and a control system to generate specific magnetic fields, ensuring a pronounced double roll flow pattern for improved molten metal flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional electromagnetic brake system with a single magnetic core structure is used, then the system structure is simple, but the fluid flow control of molten metal near the meniscus along the entire width of the mould is not optimal
Solution Approach 1:
The magnetic core structure is divided into multiple independent magnetic core sections (first, second, third, and fourth sections) arranged along the width of the mould. Each section can be controlled independently to create different magnetic field distributions across the mould width, enabling optimal fluid flow control at different locations while maintaining manageable system complexity through modular design.
Solution Approach 2:
Different magnetic core sections are equipped with different numbers of coils (e.g., first and second sections have different coil configurations than third and fourth sections) to create localized magnetic field variations. This allows the system to address specific flow control needs at different widths of the mould, such as creating double roll flow patterns in specific regions while maintaining simpler control in other areas.
2Manufacturing precision
If the magnetic core structure is divided into multiple independent sections with different coil configurations, then the fluid flow control along the entire width is optimized, but the device complexity increases
Solution Approach 1:
The system divides the magnetic core into multiple sections with different coil configurations to create localized magnetic field variations. This segmentation enables precise control of molten metal flow at different widths of the mould, achieving optimal double roll flow patterns while keeping each section's complexity manageable through modular design.
Solution Approach 2:
The system dynamically adjusts the current supplied to different coil sets (first, second, third, and fourth coil sets) to create time-varying magnetic fields that generate the desired double roll flow pattern. This dynamic control allows the system to optimize flow stabilization without requiring permanently complex structural configurations.
3Adaptability or versatility
If asymmetric flow conditions occur in slab casting, then the casting process becomes more difficult to control, but using a single electromagnetic brake system cannot provide sufficient flow control
Solution Approach 1:
The system applies different current levels to different magnetic core sections to create asymmetric magnetic field distributions that match the asymmetric flow conditions in slab casting. This localized control allows the system to adapt to and correct asymmetric flow patterns, maintaining precise flow control despite challenging casting conditions.
Solution Approach 2:
The system changes the electrical parameters (current magnitude and phase) supplied to different coil sets to adapt the magnetic field configuration to asymmetric flow conditions. By adjusting these parameters dynamically, the system maintains effective flow control precision across varying casting scenarios including asymmetric slab casting conditions.
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
The system achieves optimal magnetic field distribution and flux density, enhancing the quality of the final metal product by stabilizing the molten metal flow and reducing defects, particularly in slab casting where asymmetric flow conditions are common.
Implementation Method 1
A respective coil, sometimes referred to as a partial coil, is wound around each tooth. These coils may be connected to a drive that is arranged to feed the coils with a direct (DC) current. A static magnetic field is thereby created in the molten metal.
Implementation Method 2
The static magnetic field acts as a brake and a stabilizer for the molten metal. The flow at the upper regions, close to the meniscus of the molten metal, may thereby be controlled.
Data Source
Figure 1~2b
Figure 3a~3c
Figure 4a~4b
AI summary
The present disclosure relates to an electromagnetic brake system (7) for a metal-making process. The electromagnetic brake system comprises a two-level magnetic structure, in particular an upper magnetic core structure (8) configured to be mounted to an upper portion of a mould and a lower magnetic core structure (13) configured to be mounted to a lower portion of a mould. Lateral coils (9-1, 9-8) on the upper magnetic structure (8) are configured to be controlled to generate a first magnetic field in a first field direction and inner coils are configured to be controlled to generate a second magnetic field in a second field direction, simultaneously with the first magnetic field. The lower magnetic core structure (13) has lower coils (15-1, 15-4) which are configured to be controlled to generate a third magnetic field in the first direction simultaneously as the lateral coils and the inner coils generate their fields.