Liquid Cone Closing Position Detection in Continuous Casting
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Solution Overview
Problem
Current methods for determining the final solidification point of continuously cast metal products, such as slabs, blooms, or billets, require additional equipment and are not efficient in identifying the closing position of the liquid cone during the continuous casting process, leading to suboptimal thickness reduction and potential central segregation issues.
Innovation Solution
A method using periodic oscillating impulses applied by soft reduction roll devices along the casting line to analyze the oscillating frequency of the meniscus level in the ingot mold, comparing frequency spectra to determine if a liquid core is present, allowing for accurate identification of the closing position of the liquid cone without additional equipment, using only conventional continuous casting machine components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional equipment is used to detect the final solidification point, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The method utilizes the existing meniscus level detection system, which is already installed on continuous casting machines for monitoring steel level in the mold, and repurposes it to detect the liquid cone closing position. The same sensor and control system serve dual functions: traditional meniscus level control and identification of the kissing point location downstream, eliminating the need for additional specialized detection equipment.
Solution Approach 2:
The system uses its own existing infrastructure - the meniscus detection apparatus already present on the casting machine - to perform the measurement function. By analyzing the behavior of the existing meniscus detection system under different casting conditions and roll positions, the method extracts information about liquid cone solidification without requiring external or additional measurement devices.
2Measurement precision
If multiple bulging measurements are carried out at various points, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The method performs preliminary identification of the liquid cone closing position region using the meniscus detection system before final soft reduction operations are executed. By analyzing meniscus behavior patterns in advance, the system identifies which area along the casting line contains the kissing point, allowing subsequent soft reduction rolls to be positioned optimally without requiring multiple iterative measurements during the casting process.
Solution Approach 2:
The system continuously monitors meniscus level fluctuations and uses this feedback to determine the presence or absence of a liquid core in different areas. By analyzing the feedback signal from the meniscus detection system in relation to roll position and casting parameters, the method identifies the closing position in real-time without requiring multiple separate measurement campaigns or recursive procedures.
3Measurement precision
If casting speed is varied to identify liquid cone position, then measurement precision is improved, but productivity decreases
Solution Approach 1:
Instead of varying casting speed to identify the liquid cone position, the method applies partial action by using the existing meniscus detection system at the normal operating casting speed. The system analyzes meniscus behavior under current casting conditions to identify the closing position, avoiding the need to slow down or stop the casting process for measurements, thus maintaining productivity while achieving detection accuracy.
4Measurement precision
If Castercrown roll is used to detect final solidification, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The method repurposes the universal meniscus detection system already present on continuous casting machines to perform the specific function of identifying liquid cone closing position. Instead of installing specialized Castercrown rolls or other dedicated detection equipment, the existing meniscus sensor and control system are used to infer solidification status by analyzing meniscus level behavior under different operational conditions.
Solution Approach 2:
The method replaces mechanical detection systems like Castercrown rolls with a control-system-based approach using the existing meniscus detection apparatus. By substituting mechanical impulse-based detection with analysis of meniscus level signals already being collected for other purposes, the system achieves detection functionality without adding mechanical 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
This method allows for precise identification of the liquid cone's closing position, optimizing thickness reduction and improving product quality without interfering with the casting process, and can be performed using existing equipment, ensuring accurate positioning of soft reduction rolls for optimal results.
Implementation Method 1
applying a first periodic oscillating impulse to a first area of application represented by a first actuating cylinder, thus causing a first oscillation on the cast product
Implementation Method 2
detecting the oscillating frequency of the meniscus level in the ingot mold both during the application of said first periodic oscillating impulse and during the application of said second periodic oscillating impulse
Implementation Method 3
comparing the oscillating frequency of the meniscus level in the ingot mold with the oscillating frequency of the first area of application during the application of said first periodic oscillating impulse
Data Source
Figure 1a~1c
Figure 2a~2b
Figure 3
AI summary
A method for determining if a stretch of casting line includes the closing position of the liquid cone of a continuously cast metal product, where there is provided a casting line including an ingot mold containing the liquid metal and in which a meniscus is defined, one or more soft reduction roll devices, cylinders for actuating the one or more soft reduction devices, at least two oscillation application areas, the oscillation application areas being arranged in the one or more soft reduction roll devices. The oscillation being achieved by the rolls of the one or more soft reduction devices through the actuating cylinders. The method includes the following stages: a) applying an oscillation along the casting line to the cast product through at least two application areas in sequence; b) detecting the oscillating frequency of the meniscus level in the ingot mold; c) comparing the oscillating frequency of the meniscus level in the ingot mold with the oscillating frequency of the at least two areas of application.