Fiber Optic Fabry-Perot Mold Gap Sensing in Continuous Casting
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Solution Overview
Problem
Existing technologies lack the capability to accurately measure the mold gap and temperature profile during high-temperature solidification processes, particularly in complex shape castings and continuous casting, limiting the ability to predict and control local solidification conditions and impacting cast product quality and yield.
Innovation Solution
Employing a temperature-insensitive fiber optic Fabry-Perot interferometer-based mold gap measurement system that uses optical fiber interferometry to directly measure the mold gap and detect crystallite formation, facilitating real-time monitoring and control of the casting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If linear displacement sensors (LVDT) are used to measure mold gap, then measurement capability is provided, but device complexity increases and temperature compensation is required
Solution Approach 1:
The patent replaces mechanical displacement sensors (LVDT) with an optical fiber interferometer system. The optical fiber-based measurement system eliminates mechanical complexity by using light interference patterns to measure gap dimensions, thereby reducing mounting complexity and eliminating the need for temperature compensation mechanisms.
Solution Approach 2:
The patent introduces an optical fiber as an intermediary medium to transmit measurement information from the high-temperature mold gap environment to the external measurement system. The optical fiber acts as a mediator that can withstand the harsh thermal environment while carrying measurement data, eliminating the need for complex temperature compensation in the measurement electronics.
2Measurement precision
If linear displacement sensors are used to measure mold gap, then measurement capability is provided, but temperature compensation is required
Solution Approach 1:
The patent replaces temperature-sensitive mechanical displacement sensors with an optical measurement system that is inherently insensitive to temperature variations. The optical fiber interferometer measures gap dimensions based on light interference patterns that do not require temperature compensation, thereby eliminating temperature as a harmful factor affecting measurement precision.
3Productivity
If direct measurement of mold gap during solidification is implemented, then real-time monitoring capability is provided, but measurement system complexity increases
Solution Approach 1:
The patent uses an optical fiber as an intermediary that can be embedded within the mold structure to provide real-time measurement capability. The optical fiber serves as a simple, direct communication channel between the measurement point and the external system, enabling real-time monitoring without adding complex measurement apparatus into the high-temperature environment.
Solution Approach 2:
The patent employs an optical fiber interferometer system that can perform multiple functions: measuring mold gap dimensions, detecting crystallite formation in the flux layer, and monitoring gap variations at various positions. This multi-functional approach provides real-time monitoring capability while avoiding the need for multiple separate measurement systems, thereby managing overall system complexity.
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
Enhances cast product quality and yield by providing accurate mold gap measurements, enabling improved product quality and safety through detection of conditions leading to slab cracking and breakouts, and allowing for the development of new alloys and products.
Implementation Method 1
The optical fiber is configured to transmit light and to receive light reflected from the metal deposited in the mold
Implementation Method 2
The interferometer is configured to measure a distance between the end face of the optical fiber and the metal deposited in the mold as a function of the reflected light from within the mold received by the optical fiber
Implementation Method 3
receive light reflected from the metal deposited in the mold
Data Source
AI summary
A temperature insensitive fiber optic Fabry-Perot interferometer based mold gap measurement system that can be employed in foundry and continuous casting facilities for both non-ferrous and ferrous production applications. For steel continuous casting, the sensor is also capable of detecting crystallite formation in the mold flux layer within the mold gap by detecting reflections from both the flux layer and the steel shell to facilitate direct mold lubrication monitoring for continuous casting. These interferometers can also be easily multiplexed to perform interface shape measurements or monitor gap variations at various positions within a complex mold design. The ability to measure the cast shape exiting a continuous casting mold during operation will provide a new tool to monitor and improve product quality during operation and enhance the safety of the process through the detection of conditions that lead to slab cracking and breakouts.