Fiber-Optic Casting Level Measurement in Mold Copper Plate
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Solution Overview
Problem
Existing methods for determining the casting level in molds face challenges such as compliance with radiation protection regulations, high material and cabling costs, susceptibility to magnetic fields, and limited spatial resolution, making them inefficient and difficult to integrate into existing systems.
Innovation Solution
The use of fiber-optic temperature detection probes with optical waveguides arranged in grooves or holes within the mold copper plate, allowing for precise temperature measurement without radiation and providing high spatial resolution, ease of integration, and reusability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If radioactive particles are introduced into the mold to determine the height of the mold level, then the measurement can be performed, but compliance with radiation protection regulations becomes increasingly strict and expensive
Solution Approach 1:
The patent replaces the radioactive measurement system with a fiber-optic based optical measurement system. Instead of using radioactive particles and radiation detectors, the invention uses optical fibers to detect temperature changes in the mold copper plate, which are caused by the thermal radiation from the molten steel. This substitution eliminates all radiation safety concerns while maintaining measurement capability.
Solution Approach 2:
The patent introduces temperature as an intermediary parameter to indirectly measure the mold level height. Rather than directly measuring the position of molten steel, the system measures the temperature distribution in the mold copper plate, which varies according to the thermal radiation from the molten steel at different levels. This intermediary measurement approach avoids direct contact with radioactive or hazardous elements.
2Measurement precision
If thermocouples are used to determine the casting level by measuring temperature, then temperature measurement is achieved, but the thermocouples cannot be arranged at very close intervals and require extensive cabling
Solution Approach 1:
The patent merges multiple independent thermocouple measurements into a single fiber-optic probe system. Instead of requiring separate cabling for each measurement point, the invention uses a bundle of optical fibers that can be closely spaced and integrated into a single probe assembly. This dramatically reduces the complexity of cabling and installation while enabling much closer spacing of measurement points.
Solution Approach 2:
The patent replaces the electrical thermocouple system with an optical fiber system. Optical fibers are immune to electromagnetic interference from magnetic fields, do not require heavy shielding or complex electrical connections, and can be arranged at much closer intervals. The optical fibers transmit temperature information through light rather than electrical signals, eliminating the cabling complexity associated with thermocouples.
3Measurement precision
If thermocouples are used for temperature measurement in the mold, then temperature data is obtained, but the thermocouples are vulnerable to magnetic fields from electromagnetic brake or stirring coils
Solution Approach 1:
The patent replaces electrical thermocouples with optical fiber sensors. Optical fibers are made of dielectric materials and are completely immune to electromagnetic fields. The temperature measurement is achieved through optical properties (such as Brillouin scattering or Raman scattering) rather than electrical resistance changes, making the system inherently resistant to magnetic field interference from electromagnetic brakes or stirring coils.
4Area of stationary object
If optical fibers are used to conduct infrared radiation from points on the mold copper plate to the camera, then space requirements are reduced, but an optical fiber is required for each measuring point which must be led to the camera and connected correctly
Solution Approach 1:
The patent combines multiple optical fiber measurements into a single integrated probe assembly that can be inserted into the mold copper plate. Instead of requiring separate optical fibers to be individually routed to a camera for each measurement point, the invention integrates the optical fibers within the probe structure itself, with the probe serving as both the mounting structure and the optical transmission medium. This eliminates the complex external cabling and connection requirements.
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 reliable, high-resolution detection of the casting level without radiation concerns, reduces material and cabling needs, and is not susceptible to magnetic interference, making it easier to integrate and maintain, while providing accurate information about the shape of the mold wave.
Implementation Method 1
uses the heat radiation of the melt to determine the casting level height. The information about the temperature distribution is collected via infrared level sensors
Implementation Method 2
a fiber-optic sensor (2) for detecting the temperature at a defined height in the mold in the direction of the casting level
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3d
AI summary
The invention provides a method for the cast level measurement in a mold by means of sensors for fiber optic temperature detection, which are disposed in the mold copper plate at the height of the casting level. The invention further comprises respective sensors. Fiber optic cables are disposed in said sensors, which allow simple, reliable and highly locally resolved temperature monitoring at the height of the casting level by means of a suitable temperature analysis system. By means of the temperatures determined by the sensors, a conclusion can be made as to the exact height of the casting level. Furthermore, the shape of the casting level shaft may be determined by means of which further parameters of the casting process become accessible.