Thickness Measurement for Strip Casting Melt Control
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Solution Overview
Problem
In metal casting processes like direct strip casting, achieving homogeneous thickness of the melt is challenging due to the lack of mold wall contact, leading to irregularities such as wedges or waves, which complicates the production of uniform rolled products.
Innovation Solution
A device and method using a measuring device, either contactless with lasers and optical sensors or contact-based with tactile probes, to monitor and control the thickness of the melt or solidified product, allowing for open-loop or closed-loop control of mass flow and mold orientation to correct thickness irregularities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the melt is cast without mold wall contact (direct strip casting), then the casting process is simplified and production flexibility is improved, but thickness uniformity deteriorates leading to wedge-shaped and wave-shaped irregularities
Solution Approach 1:
The patent applies preliminary action by measuring the thickness of the melt in advance during the casting process and using this information to control the mass flow rate before thickness irregularities fully develop. This allows proactive adjustment of process parameters to maintain thickness uniformity without mold wall contact
Solution Approach 2:
The patent implements feedback control by continuously measuring the melt thickness using optical or contactless sensors and adjusting the mass flow rate based on the measured values. This closed-loop control system compensates for thickness variations in real-time, maintaining manufacturing precision while preserving the benefits of direct strip casting
2Productivity
If the mass flow is increased to maintain production rate, then productivity is improved, but thickness control precision deteriorates due to flow instability
Solution Approach 1:
The patent applies dynamics by making the mass flow rate adjustable and variable during the casting process. Instead of maintaining a constant high flow rate, the system dynamically adjusts the flow rate based on real-time thickness measurements, allowing high productivity when conditions permit while maintaining precision when variations occur
Solution Approach 2:
The patent changes the parameter of mass flow rate from a fixed value to a variable parameter that can be adjusted in response to thickness measurements. This allows the system to optimize both productivity and thickness control by modifying the flow rate parameter based on process conditions
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 the production of rolled products with more uniform dimensions and material properties by accurately measuring and controlling the thickness distribution across the width, reducing taper and waviness, and improving the quality of cast products.
Implementation Method 1
the measuring device operates by means of a laser and an optical sensor. It is advantageous if a laser for scanning the surface and a corresponding sensor are provided
Implementation Method 2
the measuring device operates by means of a laser and an optical sensor
Implementation Method 3
the measuring device operates with contact. In this case, it is effective if the measuring device operates by means of a tactile sensor, such as a probe
Data Source
AI summary
A device and a method for measuring thickness in horizontal strip casting installations for casting strip or sections. A measuring device measures the thickness of the liquid or pasty melt in the mold. The measuring device operates without contact by a laser and an optical sensor that are arranged so that the surface of the liquid or pasty melt is monitored, whereby the thickness distribution over an entire width of the melt is measured. A measuring signal is generated, and a control signal is generated based on the measuring signal in order to control a device for distributing the melt.