Online Cooperative Control for Soft and Heavy Reduction in Continuous Casting
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Solution Overview
Problem
Existing methods for soft reduction and heavy reduction in continuous casting processes face challenges in accurately determining reduction amounts, regulating reduction zones, and considering device capabilities and cracking susceptibility, leading to quality flaws like center segregation and shrinkage porosity in large-size blooms.
Innovation Solution
An online cooperative control method using a three-dimensional solidification and heat transfer model, coupled with thermo-mechanical simulations, to calculate and distribute actual reduction amounts for each roller, ensuring accurate and stable reduction while avoiding cracks, by determining the theoretical ultimate reduction amount based on device capability and cracking susceptibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a simple combination of soft reduction and heavy reduction is used, then quality improvement is achieved to a certain extent, but cooperative regulation and control becomes difficult
Solution Approach 1:
The patent implements dynamic adjustment of reduction amounts for each roller based on real-time thermal state calculations. The system continuously monitors temperature fields and solidification progress, then dynamically distributes reduction amounts across multiple rollers to achieve optimal quality improvement while maintaining ease of operation through automated control
Solution Approach 2:
The system establishes a feedback loop where thermal state measurements and solidification model predictions are continuously fed back to adjust reduction amounts. This closed-loop control enables automatic cooperative regulation of multiple rollers based on actual process conditions, resolving the contradiction between quality improvement and operational complexity
2Manufacturing precision
If reduction amounts are increased to eliminate center segregation and porosity, then quality improves, but cracking susceptibility increases
Solution Approach 1:
The patent applies different reduction amounts to different rollers based on their specific positions and the local thermal state of the bloom. By calculating the temperature field and solidification progress at each reduction zone, the system tailors the reduction amount locally to achieve defect elimination without excessive cracking risk, rather than applying uniform reduction throughout
Solution Approach 2:
The system performs preliminary calculation of the thermal state and solidification fraction before executing reduction. By predicting the thermal conditions and selecting appropriate reduction amounts in advance based on the solidification model, the system prevents cracking before it occurs while still achieving the necessary quality improvement
3Measurement precision
If device reduction capability is not considered, then theoretical reduction amounts can be calculated, but online real-time adjustment becomes inconvenient
Solution Approach 1:
The system automatically calculates and distributes reduction amounts for each roller based on thermal state calculations and device capability constraints. The automated self-service control eliminates the need for manual online adjustment, making the process both precise and operationally convenient by having the system determine optimal parameters autonomously based on real-time conditions
4Device complexity
If thermal state and solidification fraction are not calculated in real time, then control simplicity is maintained, but accurate determination of reduction zones becomes impossible
Solution Approach 1:
The patent replaces manual or mechanical control methods with computational modeling and automated calculation systems. By using thermal field simulation and solidification fraction calculation algorithms, the system achieves precise determination of reduction zones and automatic distribution of reduction amounts, transforming a potentially complex manual process into an automated computational system that is both accurate and manageable
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 enables real-time calculation and distribution of reduction amounts, ensuring reliable and stable reduction effects, avoiding cracks and improving the quality of large-size continuous casting blooms by accurately considering device capabilities and thermal states.
Implementation Method 1
Establishment of an offline three-dimensional solidification and heat transfer model for a continuous casting bloom and calculation of three-dimensional temperature fields
Implementation Method 2
calculation of three-dimensional temperature fields of continuous casting blooms of different steel types according to the offline three-dimensional solidification and heat transfer model
Implementation Method 3
Establishment of a three-dimensional reduction model for a continuous casting bloom under thermo-mechanical coupling and simulation of a reduction process
Implementation Method 4
deformations of a surface of a cast blank and a liquid core during a reduction process are calculated
Data Source
AI summary
Provided is an online cooperative control method for soft reduction and heavy reduction in bloom continuous casting. A quantitative relationship of a theoretical ultimate reduction amount to a reduction position is accurately determined according to an offline three-dimensional solidification and heat transfer model for a continuous casting bloom and a three-dimensional reduction model for a continuous casting bloom under thermo-mechanical coupling; a thermal state of a continuous casting bloom, soft reduction and heavy reduction zones, and a total reduction amount are calculated in real time with an online three-dimensional solidification and heat transfer calculation model for a continuous casting bloom; actual reduction amounts of the rollers for soft reduction and heavy reduction are calculated and distributed online based on a real-time equivalent central solid fraction and a theoretical ultimate reduction amount of each reduction roller. Online cooperative control of soft reduction and heavy reduction in bloom continuous casting is realized.