Hoisting Continuous Casting Solidification Interface Detection
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Solution Overview
Problem
In the free casting method, detecting and controlling the solidification interface is challenging, which affects the dimensional accuracy and surface quality of the casting, as the solidification interface's position is influenced by cooling gas and hoisting speed, making it difficult to maintain within a specified range.
Innovation Solution
A hoisting type continuous casting device with a shape regulating member, an imaging section, and an image analysis section to detect swinging motion and determine the solidification interface, allowing for real-time adjustments in cooling gas flow rate, hoisting speed, and furnace temperature to maintain the interface within a specified range, improving dimensional accuracy and surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling gas is applied to cool the melt that has passed through the shape regulating member, then the melt is cooled and solidification occurs, but the solidification interface position becomes difficult to detect and control
Solution Approach 1:
The patent introduces an imaging section as an intermediary device to indirectly detect the solidification interface position. Instead of directly measuring the interface, the system captures images of the melt surface and uses image analysis to determine interface position, converting an undetectable physical quantity into observable visual information.
Solution Approach 2:
The patent replaces direct mechanical or contact-based detection methods with non-contact optical detection. By using an imaging section and image analysis algorithm, the system substitutes complex mechanical sensing with simpler optical field measurement, enabling detection without physical contact with the hot melt.
2Manufacturing precision
If the solidification interface position is not controlled within a specified range, then dimensional accuracy and surface quality of the casting deteriorate
Solution Approach 1:
The patent implements a closed-loop feedback control system where the imaging section continuously monitors the solidification interface position, and the control section adjusts casting conditions based on the detected position. This feedback mechanism automatically maintains the interface within the specified range, ensuring consistent dimensional accuracy and surface quality without manual intervention.
Solution Approach 2:
The system enables self-regulation of the solidification interface position through automatic detection and control. The imaging section and control section work together to automatically adjust casting parameters, allowing the system to self-correct interface position deviations without external control, thereby simplifying operation while maintaining precision.
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 solution effectively controls the solidification interface, enhancing the dimensional accuracy and surface quality of the casting by enabling precise adjustments to the casting conditions based on real-time image analysis.
Implementation Method 1
an imaging section for capturing an image of the melt that has passed through the first shape regulating member
Implementation Method 2
the melt that has been derived is cooled by cooling gas via the shape regulating member
Implementation Method 3
a solidification interface is located on an upper side of the shape regulating member
Implementation Method 4
due to a surface film and surface tension of the melt, the melt is also derived following the starter
Data Source
AI summary
A hoisting type continuous casting device includes a keeping furnace, a first shape regulating member, an imaging section, an image analysis section, and a casting control section. The keeping furnace keeps a melt. The first shape regulating member is mounted in the vicinity of a molten surface of the melt kept in the keeping furnace and regulates a cross-sectional shape of a casting to be casted by the melt passing therethrough. The imaging section captures an image of the melt that has passed through the first shape regulating member. The image analysis section detects swinging motion in the melt from the image and determines a solidification interface based on presence or absence of the swinging motion. The casting control section changes a casting condition when the solidification interface determined by the image analysis section is not within a predetermined reference range.