Meniscus Flow Control Device for Molten Steel Slab Casting
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Solution Overview
Problem
Current methods fail to effectively visualize and control the flow of a molten steel meniscus within a mold during continuous casting, leading to defects in slab quality due to inadequate real-time monitoring and control of the meniscus flow pattern.
Innovation Solution
A meniscus flow control device equipped with temperature measurers, a magnetic field generation unit, and a flow pattern classification unit that analyzes temperature differences to classify flow patterns as normal or abnormal, adjusting the magnetic field operation to maintain or correct the meniscus flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature measurers are installed at multiple positions to measure the entire meniscus flow, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The mold width is divided into multiple measurement zones with temperature measurers installed at specific positions (both sides and center). This segmentation allows comprehensive meniscus flow measurement across the entire width without requiring continuous coverage, balancing measurement precision with device simplicity.
Solution Approach 2:
Temperature measurers serve as intermediary elements that indirectly measure meniscus flow characteristics. By measuring temperature distribution at multiple positions, the system infers flow patterns without direct contact with the molten steel, simplifying the measurement system while maintaining precision.
2Manufacturing precision
If real-time meniscus flow measurement is implemented, then manufacturing precision is improved, but ease of operation deteriorates due to high-temperature environment
Solution Approach 1:
The system replaces direct visual observation and manual measurement methods with automated temperature-based sensing. Temperature measurers and a controller automatically monitor and analyze meniscus flow in real-time, eliminating the need for workers to physically access the high-temperature zone while maintaining manufacturing precision.
Solution Approach 2:
The measurement system operates autonomously without requiring manual intervention in the high-temperature environment. The temperature measurers continuously self-monitor the meniscus flow, and the controller automatically processes the data, making the system easy to operate despite the challenging thermal conditions.
3Reliability
If mold flux is applied to lubricate the meniscus, then reliability is improved, but measurement precision deteriorates due to obscured view
Solution Approach 1:
Temperature measurers act as intermediaries that measure meniscus flow through thermal fields rather than direct visual contact. This allows continuous monitoring even when mold flux obscures the visual view, maintaining both the lubrication function of the flux and the measurement precision.
Solution Approach 2:
Visual observation methods are replaced with thermal sensing technology. The temperature measurers detect thermal radiation and conduction from the meniscus, providing measurement capability that is not blocked by mold flux, thereby maintaining measurement precision while preserving the reliability benefits of flux application.
4Adaptability or versatility
If multiple temperature measurers are installed to measure varying slab widths, then adaptability is improved, but device complexity increases
Solution Approach 1:
The measurement system is segmented into fixed-position temperature measurers installed at both sides and center of the mold. This segmentation provides adequate measurement coverage for various slab widths without requiring continuous adjustment of the number or position of sensors, achieving adaptability while controlling device complexity.
Solution Approach 2:
The temperature measurers are designed to serve multiple functions: measuring temperature distribution, detecting meniscus flow patterns, and adapting to different slab widths. This multi-functionality allows a fixed configuration of sensors to handle variable production conditions, improving adaptability without increasing device 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
Enables real-time visualization and control of the meniscus flow, reducing defects in slab quality by accurately monitoring and adjusting the meniscus flow pattern, regardless of slab width variations.
Implementation Method 1
a plurality of temperature measurers measuring a temperature in a width direction of a mold receiving molten steel therein at a plurality of positions
Implementation Method 2
a magnetic field generation unit installed outside the mold to generate magnetic fields and thereby to control the flow of the molten steel
Implementation Method 3
a flow pattern classification unit analyzing the meniscus flow form detected by the flow detection unit to classify the meniscus flow form into one flow pattern type of a plurality of previously stored flow pattern types
Data Source
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AI summary
A meniscus flow control device according to the present invention comprises: a meniscus flow detection unit for detecting, in a meniscus flow form of molten steel, relative temperature values for positions measured by a plurality of temperature measurers, and relatively comparing the temperature values measured by the plurality of temperature measurers to thereby determine the flow state of the molten steel meniscus to be normal or abnormal; a magnetic field generation unit, installed outside a mold, for generating a magnetic field and controlling the flow of the molten steel by means of the magnetic field; and a flow control unit for maintaining the operation of the magnetic field generation unit in the current state when the meniscus flow state detected by the meniscus flow detection unit is determined to be normal, and for controlling the magnetic field generation unit to adjust the meniscus flow to be normal when the detected meniscus flow state is determined to be abnormal. Therefore, according to the embodiments of the present invention, a plurality of temperature measurers, installed on the upper side of the mold, detect temperatures for positions in the width direction of the meniscus and display the same relatively. Accordingly, the temperatures are converted into relative heights for positions in the molten steel meniscus, thereby allowing the meniscus flow state to be detected. In addition, it is easy to conduct monitoring of the normal or abnormal state of the molten steel meniscus, and it is possible to reduce the occurrence of molten steel meniscus defects.