Laser Mold Powder Depth Control for Continuous Casters
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Continuous casters face challenges in maintaining a consistent granular mold powder layer thickness due to variable consumption rates, leading to issues like 'roping' and slag production, which can result in defects or catastrophic 'caster breakout', as manual estimation and application are inadequate and hazardous.
Innovation Solution
A method using a TOF laser sensor or small diameter beam laser in conjunction with a high-pressure gas puff to accurately measure granular powder depth and underlying liquid layer height, enabling feedback control for precise powder feed and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual estimation and application of mold powder is used, then human operators can apply powder based on visual assessment, but the powder layer thickness becomes inconsistent leading to defects like roping and slag production
Solution Approach 1:
The patent replaces manual visual estimation with an automated optical measurement system using a laser distance sensor. The laser sensor objectively measures powder layer thickness at multiple locations, eliminating human error and subjectivity. This optical measurement system continuously monitors and provides precise data for feedback control, ensuring consistent powder layer thickness and preventing defects like roping and slag production.
Solution Approach 2:
The patent implements a closed-loop feedback control system where laser measurements of powder layer thickness are continuously fed back to the powder delivery mechanism. The control system adjusts powder delivery rates based on real-time thickness measurements, maintaining consistent powder layer depth. This feedback mechanism prevents both excessive powder application (roping) and insufficient coverage (slag production).
2Object-affected harmful factors
If remote control of variable rate granular powder feeder is implemented, then human operators are protected from hazardous conditions, but accurate determination of granular powder depth across the mold top remains challenging
Solution Approach 1:
The patent replaces manual depth estimation with an automated laser distance measurement system that operates remotely from the hazardous caster environment. The laser sensor accurately measures powder depth across the mold top without requiring human operators to be in dangerous positions. Multiple measurement points provide comprehensive depth data for precise feedback control.
Solution Approach 2:
The patent introduces a laser distance sensor as an intermediary measurement tool that bridges the gap between remote powder delivery control and accurate depth determination. The sensor acts as a mediator, providing precise depth data from hazardous areas without exposing operators to risk, while enabling accurate feedback control of powder application.
3Ease of operation
If consistent rate powder feeding is used, then powder delivery is simplified, but the desired powder thickness cannot be maintained across the entire top area leading to roping or slag production
Solution Approach 1:
The patent transforms the static, consistent-rate powder feeding system into a dynamic, variable-rate system controlled by laser measurements. The powder delivery mechanism adjusts its operation in real-time based on measured powder depth at multiple locations. This dynamic control maintains optimal powder thickness across the entire caster top, preventing both roping (excessive powder) and slag production (insufficient powder) while remaining operationally simple through automation.
Solution Approach 2:
The patent implements feedback control where laser depth measurements continuously inform powder delivery rate adjustments. The system automatically increases or decreases powder delivery at specific locations based on real-time thickness measurements, maintaining uniform powder layer depth across the entire caster top. This eliminates the need for manual intervention while achieving precise thickness control.
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 solution allows for the maintenance of a constant powder layer thickness, reducing defects and ensuring safe operation by automating the measurement and application of granular mold powder, thereby preventing 'roping' and 'caster breakout' while protecting human operators from hazardous conditions.
Implementation Method 1
the distance measurement obtained from a TOF (Time of Flight) laser sensor is accurate and robust when utilized to measure the top surface powder height
Implementation Method 2
a switchable flow of gas projected upon the powder layer effective to form a cavity sufficiently deep to expose the underlying solid or liquid
Data Source
AI summary
Disclosed is a method of using laser sensors to measure the top surface of the granular flux powder height at the top of the continuous caster. Additionally, the laser sensor measures the height of the underlying sintered or liquid flux level absent the powder. This disclosure includes a method of utilizing a laser sensor and a gas puff to determine both the granular powder depth and the level of the underlying solid or liquid layer. The granular powder depth measurement then is utilized in a mold powder deposition system to permit feedback control so as to maintain the granular powder thickness.