Ultrasonic Crater End Detection in Continuous Casting
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Solution Overview
Problem
Current methods for detecting the crater end of continuously cast products are limited by the need for calibration based on physical properties that vary with chemical components, leading to inaccurate measurements and restricted application ranges, especially when using ultrasonic waves or heat condition equations.
Innovation Solution
The method involves installing ultrasonic shear wave and longitudinal wave sensors to detect the crater end by calibrating the calculation formula or heat condition equation based on the position of the shear wave sensor, allowing for accurate detection regardless of chemical components and casting conditions, using the sensitivity of ultrasonic velocity changes in solid and liquid phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If ultrasonic wave methods or heat condition equations are used to detect crater end, then detection capability is provided, but measurement precision deteriorates due to the need for calibration based on physical properties that vary with chemical components
Solution Approach 1:
The patent replaces traditional mechanical calibration methods (slab rivet) with electromagnetic ultrasonic sensing. The electromagnetic ultrasonic transmitter generates ultrasonic waves that propagate through the continuously cast product, and the receiver detects these waves to determine solidification state, eliminating the need for physical calibration specimens.
Solution Approach 2:
The patent utilizes changes in ultrasonic wave propagation characteristics (velocity, attenuation) as the material transitions from liquid to solid phase. By monitoring these parameter changes in the ultrasonic signals, the system can accurately detect the crater end position without requiring calibration for different chemical compositions.
2Measurement precision
If calibration with slab rivet is performed to improve measurement accuracy, then detection precision is improved, but device complexity and operation difficulty increase
Solution Approach 1:
The electromagnetic ultrasonic sensing system is self-calibrating through the inherent physical properties of the continuously cast product itself. The ultrasonic waves propagate through the material being measured, and the system automatically adapts to different chemical compositions and casting conditions without requiring external calibration standards or manual intervention.
Solution Approach 2:
The patent extracts the calibration requirement entirely from the measurement system. Instead of needing external calibration artifacts (slab rivets), the system uses the continuously cast product itself as the measurement medium, eliminating the complex calibration process while maintaining measurement accuracy.
3Productivity
If casting speed is increased to improve productivity, then productivity is improved, but the crater end moves downstream beyond the support rolls range causing quality deterioration
Solution Approach 1:
The patent implements real-time feedback control by continuously monitoring ultrasonic wave propagation characteristics along the casting direction. The system detects the crater end position dynamically and provides feedback to control the casting process, ensuring the crater end remains within the optimal zone even at high casting speeds.
Solution Approach 2:
The system performs preliminary detection of solidification progress using ultrasonic waves before the crater end reaches critical positions. This allows advance adjustment of casting parameters to maintain quality, preventing the crater end from moving beyond the support rolls range.
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 approach enables precise detection of the crater end with high accuracy, overcoming limitations of previous methods by eliminating the need for calibration with a slab rivet and improving productivity and quality by accurately positioning the crater end within the casting process.
Implementation Method 1
installing an ultrasonic shear wave sensor for transmitting an ultrasonic shear wave to a continuously cast product and receiving the transmitted ultrasonic shear wave
Implementation Method 2
installing an ultrasonic longitudinal wave sensor for transmitting an ultrasonic longitudinal wave to a continuously cast product and receiving the transmitted ultrasonic longitudinal wave
Implementation Method 3
using the sensitivity of ultrasonic velocity changes in solid and liquid phases
Data Source
AI summary
A method for detecting a crater end of a continuously cast product including installing an ultrasonic shear wave sensor for transmitting an ultrasonic shear wave to a cast product and receiving the transmitted ultrasonic longitudinal wave and an ultrasonic longitudinal wave sensor for transmitting an ultrasonic longitudinal wave to the cast product and receiving the transmitted ultrasonic longitudinal wave at the same position in a continuous casting machine or at positions apart from each other in a casting direction, but at the same position in a transverse direction of the cast product, detecting based on variations of an ultrasonic signal received by the ultrasonic shear wave sensor that the crater end of the cast product is matched with the installed position of the ultrasonic shear wave sensor, calibrating a calculation formula for determining the crater end and determining the crater end.