Hinged Soft Reduction Segment for Precise Slab Thickness Control
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Solution Overview
Problem
Current continuous casting machines for slabs face limitations in achieving precise and flexible soft reduction due to their design, leading to inefficiencies in reducing segregation and central porosity, and existing solutions either require excessive plant engineering complexity or are not sufficiently flexible.
Innovation Solution
A soft reduction segment with an upper support divided into two parts connected by a hinge, allowing independent adjustment of the inclination between these parts and using multiple actuators to control roller positions, reducing discretization and enabling finer control over the reduction process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-piece upper support and lower support are used with limited actuators, then the device complexity is reduced, but the manufacturing precision and flexibility of soft reduction profile are insufficient
Solution Approach 1:
The upper support is divided into multiple modular segments (first segment, second segment, third segment) that can be independently adjusted. Each segment has its own actuators and adjustment units, allowing precise control of the soft reduction profile while maintaining manageable system complexity through modular architecture.
Solution Approach 2:
The support structure incorporates dynamic adjustment capabilities with multiple actuators that can independently control the position and inclination of different segments. This allows the system to adaptively adjust the soft reduction profile in real-time, achieving high manufacturing precision without requiring a completely rigid and complex single-piece structure.
2Manufacturing precision
If multiple actuators are used to control each roller position for precise thickness profile control, then the manufacturing precision is improved, but the device complexity and plant engineering complexity increase substantially
Solution Approach 1:
Each actuator is designed to perform multiple functions: controlling roller position, adjusting segment inclination, and maintaining slab support. The adjustment units serve both positioning and orientation functions, reducing the total number of actuators needed while maintaining precise thickness profile control.
Solution Approach 2:
Multiple control functions are merged into integrated adjustment units that combine actuators with mechanical linkage systems. The connection elements and hinges are integrated into the segment structure, reducing the number of separate components and simplifying the overall actuator system while maintaining precision control.
3Device complexity
If the upper support is made as a single piece with fixed structure, then the device complexity is reduced, but the adaptability and flexibility of the soft reduction process are limited
Solution Approach 1:
The upper support is segmented into multiple independent modules that can be individually adjusted. Each segment can be controlled separately, providing adaptability to different reduction profiles and casting conditions while keeping each module's structure relatively simple.
Solution Approach 2:
The support structure transitions from a fixed single-piece design to a dynamic modular system with adjustable segments. The connection elements and hinges enable movement and reconfiguration, allowing the system to adapt to various soft reduction requirements without requiring complex reconfiguration of the entire structure.
4Device complexity
If discretization is increased by using fixed segments, then the device complexity is reduced, but the productivity and efficiency of soft reduction process are limited
Solution Approach 1:
The segment structure incorporates dynamic adjustment capabilities that allow continuous modification of the soft reduction profile during operation. This enables more efficient processing by optimizing the reduction parameters in real-time without requiring frequent stops or manual reconfiguration, thereby improving productivity while maintaining manageable device complexity.
Data Source
AI summary
A soft reduction segment of a continuous casting machine, said segment being suitable for carrying out a soft reduction of a slab exiting from said continuous casting machine, the segment comprisingan upper support for supporting upper rollers;a lower support for supporting lower rollers;adjustment units having pairs of actuators arranged to adjust a relative inclination between the upper support and the lower support and, thus, between the upper rollers and the lower rollers;wherein the upper support is divided into a first part, which is proximal to the slab run-in end, and a second part, which is proximal to the slab run-out end, said first part and said second part being connected to each other by at least one first hinge.