Magnetic Field Level Detection in Casting Crystallizers
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Solution Overview
Problem
Existing devices for detecting the level of liquid metal in casting apparatuses, such as continuous casting crystallizers, face challenges in accurately measuring the meniscus level due to interference from protective powder layers and copper walls, leading to inaccuracies and complexity, especially for large cast products.
Innovation Solution
A device with a box-like structure attached to the crystallizer's upper end, featuring a magnetic field generation and detection system that protrudes inside the crystallizer, generating a variable magnetic field to induce currents and detect the reaction field, allowing precise measurement of the liquid metal level without interference from crystallizer walls or powder layers, using a single or dual coils configuration with a control unit for signal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single electromagnetic device is used for level detection, then device complexity is reduced, but the detection zone is limited and cannot cover large cast products
Solution Approach 1:
The patent combines multiple electromagnetic coils (first and second excitation coils, first and second reception coils) into a single integrated device structure. This merging approach maintains low device complexity while achieving coverage of large detection zones through coordinated operation of multiple coils within one unit.
Solution Approach 2:
The patent transitions from single-point detection to multi-point detection by arranging coils at different positions around the crystallizer. This dimensional expansion allows the device to cover the entire perimeter of large cast products while maintaining a unified device structure.
2Area of stationary object
If multiple devices are used to detect level in large ingot molds, then detection coverage is improved, but application complexity and signal processing complexity increase
Solution Approach 1:
The patent merges the functionality of multiple separate detection devices into a single integrated device. By combining multiple excitation and reception coils within one device structure, it achieves comprehensive detection coverage without requiring multiple separate installations, thereby reducing application complexity.
Solution Approach 2:
The integrated device performs multiple detection functions simultaneously through its array of coils. The device can detect liquid metal level at multiple positions around the crystallizer perimeter, providing universal coverage for large ingot molds while simplifying installation and signal processing compared to multiple separate devices.
3Measurement precision
If the magnetic field is generated close to the crystallizer wall, then detection precision is improved, but deviation effects from copper walls increase
Solution Approach 1:
The patent introduces a non-conductive intermediary medium (such as air or insulation material) between the electromagnetic coils and the copper crystallizer wall. This intermediary reduces the harmful deviation effects by preventing direct interaction between the magnetic field and the conductive copper wall, while still allowing sufficient field penetration for accurate detection.
Solution Approach 2:
The patent extracts the harmful interaction between the magnetic field and copper walls by positioning the coils at an optimized distance and using shielding structures. This separation removes the source of deviation effects while preserving the essential magnetic field interaction needed for detection, thereby improving measurement 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
Enables precise detection of the average liquid metal level across a wide area, reducing errors from copper walls and powder layers, providing a reliable, economical, and simplified method for large cast products, with improved signal processing for accurate level determination.
Implementation Method 1
a device which exploit the variable magnetic field generated by an excitation coil localized in proximity to a perimeter point on the upper end of the crystallizer, in order to induce induced currents in the liquid steel present in the ingot mold. By striking the liquid steel with a variable magnetic field, induced currents are known to be generated therein. The induced currents in the liquid steel, in their turn, generate an induced reaction magnetic field which is detected by suitable reception coils of the device
Data Source
AI summary
A device to detect the level of liquid metal (M) in a casting apparatus includes a box-like structure associated in correspondence with an upper end of a crystallizer. The box-like structure has a peripheral cavity inside in which a device for the generation and detection of a variable magnetic field is disposed. The device for the generation and detection extends for a segment beyond an inner corner of the crystallizer so as to face directly into the open top of the crystallizer.