Inductive Distance Sensors for Continuous Casting Mold Monitoring

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Solution Overview

Problem

Existing methods for continuous casting of aluminum alloy metal strands are hindered by warping of the narrow sides, leading to instability and potential sticking in the mold, which is difficult to detect in time for effective intervention, especially under harsh production conditions.

Innovation Solution

The implementation of distance sensors, preferably inductive and arranged near or on the center line of the sprue block surface, to measure the distance between the sprue block and the metal strand foot, allowing early detection of sticking and warping, with additional sensors for precise monitoring and control of the cooling process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If distance sensors are installed on the sprue block to enable early detection of sticking and warping, then the reliability of the casting process is improved, but the device complexity increases

Engineering Contradiction:

Improvecasting process reliabilityVSAvoidmeasurement device complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical measurement systems with inductive distance sensors that use electromagnetic fields to measure the position of the metal strand. This substitution reduces mechanical complexity while improving measurement reliability and enabling continuous monitoring during the casting process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The inductive distance sensors are integrated directly into the sprue block structure, allowing the sprue block to perform both its traditional function of supporting the metal strand and the additional function of housing measurement sensors. This self-service approach reduces overall system complexity by combining multiple functions in existing components.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If inductive distance sensors are used to measure the distance between the sprue block and metal strand foot, then the measurement precision is improved, but the ease of operation deteriorates due to harsh environmental conditions

Engineering Contradiction:

Improvedistance measurement precisionVSAvoidsensor operation ease

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent employs robust inductive distance sensors that are designed to withstand harsh casting environments including high temperatures, metal spatter, and water cooling. These sensors are positioned to be protected from the most extreme conditions, allowing them to operate reliably without requiring frequent replacement or maintenance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The inductive distance sensors measure distance through electromagnetic fields that can penetrate the sprue block material, allowing measurement without direct contact between the sensor and the metal strand. This intermediary electromagnetic field approach enables precise measurement while protecting the sensor from harsh physical contact with molten metal and spatter.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables early intervention in the casting process to prevent sticking and warping, ensuring stable production by providing reliable and precise measurement data even in challenging environmental conditions, thereby improving the continuous casting process.

Implementation Method 1

The at least one distance sensor preferably inductively measures the distance between the sprue block surface and the surface of the metal strand foot facing the sprue block during continuous casting

Methodology Applied

Scientific EffectInductive sensing: Electromagnetic Induction

Implementation Method 2

the molten metal is passed through a mold and cooled down by primary and secondary coolants to form a metal strand or rolling slab

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 3

the at least one casting table that can be lowered relative to at least one mold

Methodology Applied

Scientific EffectGravitational force: Gravitation

Data Source

PatentEP3546086B1Method for continuously casting a metal strand using a mould and a casting stone

Publication Date: 2021.01.06 HYDRO ALUMINIUM ROLLED PRODUCTS GMBH

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AI summary

The invention relates to a device for continuous casting of at least one metal strand (1), in particular at least one rolling ingot from a melt of an aluminum alloy, comprising at least one mold (2), at least one casting table (3) that can be lowered relative to at least one mold (2), and at least one sprue (4), wherein the at least one sprue (4) is assigned to each mold (2) and is arranged on the at least one lowerable casting table (3).The objective of proposing a device for continuous casting of a metal strand, in particular a rolling ingot from a melt of an aluminum alloy, which offers improved intervention possibilities in the continuous casting process and also ensures these permanently in production operation, is achieved by the fact that the at least one sprue (4) has at least one distance sensor (5, 6, 7) which is arranged near or on the center line (9a) running perpendicular to the broad side of the associated mold, preferably in the center (10) of the sprue surface (11) of the sprue (4) and the at least one distance sensor (5, 6, 7) can measure the distance between the sprue surface (11) and the surface of the metal strand foot facing the sprue (4) during continuous casting.