Continuous Casting Slab Cutting Control With Corrective Second Cutter
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Solution Overview
Problem
Existing continuous casting equipment-connected rolling systems face challenges in improving product yield and productivity due to inaccuracies in cutting position control, leading to inefficiencies and potential scrap generation.
Innovation Solution
A cutting position control device utilizing an arithmetic processing circuit to calculate and adjust cutting positions for upstream and downstream cutters based on production schedules and material information, enabling precise control and correction of cutting positions to optimize slab lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cutter is used to cut slabs based on production schedule, then the control system is simple, but the product yield is reduced due to inaccurate cutting positions and inability to optimize slab lengths
Solution Approach 1:
The system divides the cutting operation into two stages: a first cutter performs initial cutting based on production schedule, and a second cutter performs corrective cutting to achieve precise target lengths. This segmentation allows each cutter to have specialized functions, improving overall cutting accuracy and product yield without requiring complete system redesign
Solution Approach 2:
The control device acts as an intermediary between production scheduling and cutting execution. It calculates target cutting positions, determines whether corrective cutting is needed, and coordinates both cutters to work together. This intermediary function optimizes the cutting process and maximizes product yield from each slab
2Productivity
If cutting positions are not precisely controlled, then the processing is simple and fast, but scrap is generated and product yield decreases
Solution Approach 1:
The control device performs preliminary calculation of target cutting positions before actual cutting occurs. By determining the optimal cutting positions in advance based on slab length measurements and production requirements, the system ensures accurate cutting while maintaining efficient processing speed, preventing scrap generation before it happens
Solution Approach 2:
The system measures actual slab lengths and uses this feedback to determine whether corrective cutting is needed. The control device compares measured lengths with target lengths and activates the second cutter only when necessary, creating a feedback loop that eliminates scrap while maintaining high productivity
3Productivity
If the first cutter cuts all slabs to target length, then the process is efficient, but variations in slab length cause inaccuracies and yield loss
Solution Approach 1:
The system dynamically adjusts the cutting strategy based on measured slab lengths. When slab lengths vary from targets, the control device activates corrective cutting by the second cutter. This dynamic adaptation maintains both high efficiency (by not always using the second cutter) and high precision (by correcting when needed)
Solution Approach 2:
The control device changes the cutting parameter (whether to activate the second cutter) based on the measured slab length parameter. This conditional parameter change allows the system to maintain efficiency for slabs that are already close to target length while achieving high precision for slabs requiring correction
Data Source
AI summary
A cutting position control device according to an embodiment includes an arithmetic processing circuit that receives an input of first data relating to a production schedule and material information of a material to be produced, uses the first data to calculate a first cutting position of a first cutter for a first slab cast by continuous casting equipment, generates a first parameter for setting the first cutting position for a control program introduced to a process control device, and determines whether or not to use a second cutter to further cut a second slab of a second length cut from the first slab based on the first parameter by comparing the second length and a first length set to be from a front end of the first slab to the first cutting position, wherein the second cutter is located downstream of the first cutter.