Crack Detection in Continuous Casting Mold Shells
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Solution Overview
Problem
Current methods for diagnosing cracking in solidified shells during continuous casting processes lack real-time monitoring and efficient detection, leading to increased costs and failure rates due to inadequate crack detection and correction.
Innovation Solution
A system comprising a matrix of temperature sensors divided into groups to calculate temperature differences, with a processor determining cracking by comparing these differences to reference values, allowing for real-time diagnosis of longitudinal cracking in solidified shells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional crack detection methods are used, then the system is simpler, but real-time monitoring capability is lost and detection accuracy decreases
Solution Approach 1:
The mold surface is divided into multiple measurement zones with temperature sensors arranged in a matrix pattern. This segmentation allows localized temperature monitoring at specific positions, enabling precise crack detection while maintaining a manageable system structure through modular sensor placement.
Solution Approach 2:
Traditional mechanical crack detection methods are replaced with a thermal field-based detection system. Temperature sensors measure thermal radiation or temperature changes to detect cracks, substituting mechanical inspection with a non-contact thermal measurement approach that provides real-time monitoring capability.
2Reliability
If temperature sensors are arranged in a full matrix across the mold, then detection coverage is maximized, but system complexity and cost increase
Solution Approach 1:
Instead of placing sensors uniformly across the entire mold surface, temperature sensors are strategically positioned only in high-risk crack-prone zones. This partial action approach provides sufficient detection reliability for critical areas while avoiding the complexity and cost of full-surface sensor coverage.
Solution Approach 2:
Different regions of the mold are assigned different sensor densities based on their crack susceptibility. Areas with higher crack risk receive more concentrated sensor placement, while lower-risk areas have fewer or no sensors. This local quality differentiation optimizes detection reliability where needed while reducing overall system 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 accurate and timely detection of longitudinal cracking, reducing the need for costly slab corrections and improving the reliability of the continuous casting process by identifying cracks early.
Implementation Method 1
a plurality of temperature sensors arranged in a matrix form in a mold... from the temperatures detected by the plurality of temperature sensors
Data Source
AI summary
The present invention relates to a system and method for diagnosing cracking in a solidified shell in a mold, in which whether longitudinal cracking has occurred in the solidified shell can be diagnosed in real time by using a variation in temperature of the solidified shell in the mold during a continuous casting process. The system comprises: a plurality of temperature sensors arranged in a matrix form in a mold, wherein the plurality of temperature sensors are divided into a first group and a second group based on where cracking occurs; and a processor configured to: calculate a temperature difference between the temperature of the first group and the temperature of the second group from the temperatures detected by the plurality of temperature sensors; and determine, using the calculated temperature difference, whether cracking has occurred in a solidified shell discharged from the mold.