U.S. patent application number 15/596795 was filed with the patent office on 2017-11-16 for system and method for adjusting continuous casting components.
The applicant listed for this patent is Golden Aluminum, Inc.. Invention is credited to Leland Lorentzen.
Application Number | 20170326629 15/596795 |
Document ID | / |
Family ID | 60297329 |
Filed Date | 2017-11-16 |
United States Patent
Application |
20170326629 |
Kind Code |
A1 |
Lorentzen; Leland |
November 16, 2017 |
SYSTEM AND METHOD FOR ADJUSTING CONTINUOUS CASTING COMPONENTS
Abstract
A method includes: sensing a defect on a cast strip surface, the
cast strip being cast from molten metal or alloy by a casting
system, determining an adjustment amount and/or direction of a
casting system component based on the identified surface defect,
and providing the adjustment amount and/or direction to an operator
for adjustment of the casting system component and/or commanding
that the casting system component be adjusted by the adjustment
amount and/or direction.
Inventors: |
Lorentzen; Leland; (Erie,
CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Golden Aluminum, Inc. |
Fort Lupton |
CO |
US |
|
|
Family ID: |
60297329 |
Appl. No.: |
15/596795 |
Filed: |
May 16, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62337136 |
May 16, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01N 21/8903 20130101;
G01N 29/07 20130101; G01N 19/08 20130101; G01N 2021/8416 20130101;
B22D 11/22 20130101; G01N 2291/02854 20130101; G01N 13/00 20130101;
G01N 21/8914 20130101; G01B 21/08 20130101; B22D 11/003 20130101;
G01N 2021/8918 20130101; G01N 29/4427 20130101 |
International
Class: |
B22D 11/22 20060101
B22D011/22; B22D 11/00 20060101 B22D011/00 |
Claims
1. A method, comprising: sensing, by a sensor, a defect on a cast
strip surface, the cast strip being cast from molten metal or alloy
by a casting system; determining, by a microprocessor executable
control system, an adjustment amount and/or direction of a casting
system component based on the identified surface defect; and the
microprocessor executable control system at least one of providing
the adjustment amount and/or direction to an operator for
adjustment of the casting system component and commanding that the
casting system component be adjusted by the adjustment amount
and/or direction.
2. The method of claim 1, wherein the casting system is a block
caster, wherein the casting system component is an adjustment point
on a chilling block, and the surface defect is an impression of a
block joint.
3. The method of claim 2, wherein the sensor is a plurality of
sensors comprising first and second sensor sets, each sensor in the
first sensor set scanning a portion of an upper surface of the cast
strip and each sensor in the second sensor set scanning a portion
of a lower surface of the cast strip, and each sensor in the first
sensor set opposing a corresponding sensor in the second sensor set
and wherein each opposing pair of sensors in the first and second
sensor sets are in line with a respective adjustment point.
4. The method of claim 3, wherein the sensor is positioned such
that the sensed defect is caused by the casting system component to
be adjusted and wherein the sensors are one or more of a laser
radar detector, a mechanical displacement device, an imaging
device, an optical 3d measuring systems, and an ultrasound
transducer.
5. The method of claim 2, wherein the microprocessor executable
control system senses a defect by measuring a thickness of the cast
strip and compares the measured thickness to a predetermined
thickness for the cast strip and determines the adjustment amount
and/or direction based on a difference between the measured and
predetermined thicknesses.
6. The method of claim 1, wherein the molten metal or alloy is one
or more of manganese, a manganese alloy, aluminum, an aluminum
alloy, copper, a copper alloy, iron, and an iron alloy.
7. A tangible and non-transitory computer readable medium,
comprising microprocessor executable instructions operable to
perform functions comprising: one or more instructions to receive
sensor information indicating existence of a defect on a cast strip
surface, the cast strip being cast from molten metal or alloy by a
casting system; one or more instructions to determine an adjustment
amount and/or direction of a casting system component based on the
identified surface defect; and one or more instructions to at least
one of: provide the adjustment amount and/or direction to an
operator for adjustment of the casting system component, and
command that the casting system component be adjusted by the
adjustment amount and/or direction.
8. The computer readable medium of claim 7, wherein the casting
system is a block caster, wherein the casting system component is
an adjustment point on a chilling block, and the surface defect is
an impression of a block joint.
9. The computer readable medium of claim 8, wherein the sensor is a
plurality of sensors comprising first and second sensor sets, each
sensor in the first sensor set scanning a portion of an upper
surface of the cast strip and each sensor in the second sensor set
scanning a portion of a lower surface of the cast strip, and each
sensor in the first sensor set opposing a corresponding sensor in
the second sensor set and wherein each opposing pair of sensors in
the first and second sensor sets are in line with a respective
adjustment point.
10. The computer readable medium of claim 9, wherein the sensor is
positioned such that the sensed defect is caused by the casting
system component to be adjusted and wherein the sensors are one or
more of a laser radar detector, a mechanical displacement device,
an imaging device, an optical 3d measuring systems, and an
ultrasound transducer.
11. The computer readable medium of claim 8, wherein the one or
more instructions senses a defect by measuring a thickness of the
cast strip, compares the measured thickness to a predetermined
thickness for the cast strip, and determines the adjustment amount
and/or direction based on a difference between the measured and
predetermined thicknesses.
12. The computer readable medium of claim 7, wherein the molten
metal or alloy is one or more of manganese, a manganese alloy,
aluminum, an aluminum alloy, copper, a copper alloy, iron, and an
iron alloy.
13. A casting system, comprising: a nozzle to provide a molten
metal or metal alloy; a casting assembly to cool and mold the
molten metal or metal alloy to form a cast strip; a sensor to sense
a defect on a surface of the cast strip surface; and a
microprocessor executable control system operable to determine an
adjustment amount and/or direction of a casting assembly component
based on the identified surface defect and at least one of: (a)
provide the adjustment amount and/or direction to an operator for
adjustment of the casting assembly component and (b) command that
the casting assembly component be adjusted by the adjustment amount
and/or direction.
14. The casting system of claim 13, wherein the casting assembly
comprises a block caster, wherein the casting assembly component is
an adjustment point on a chilling block, and the surface defect is
an impression of a block joint.
15. The casting system of claim 14, wherein the sensor is a
plurality of sensors comprising first and second sensor sets, each
sensor in the first sensor set scanning a portion of an upper
surface of the cast strip and each sensor in the second sensor set
scanning a portion of a lower surface of the cast strip, and each
sensor in the first sensor set opposing a corresponding sensor in
the second sensor set and wherein each opposing pair of sensors in
the first and second sensor sets are in line with a respective
adjustment point.
16. The casting system of claim 15, wherein the sensor is
positioned such that the sensed defect is caused by the casting
assembly component to be adjusted and wherein the sensors are one
or more of a laser radar detector, a mechanical displacement
device, an imaging device, an optical 3d measuring systems, and an
ultrasound transducer.
17. The casting system of claim 14, wherein the microprocessor
executable control system senses a defect by measuring a thickness
of the cast strip and compares the measured thickness to a
predetermined thickness for the cast strip and determines the
adjustment amount and/or direction based on a difference between
the measured and predetermined thicknesses.
18. The casting system of claim 13, wherein the molten metal or
alloy is one or more of manganese, a manganese alloy, aluminum, an
aluminum alloy, copper, a copper alloy, iron, and an iron
alloy.
19. The casting system of claim 13, further comprising: a launder
to receive the molten metal or metal alloy from a furnace; and a
tundish and/or headbox to receive the molten metal or metal alloy
from the furnace and provide the melt to the nozzle.
20. The casting system of claim 13, wherein the casting assembly
comprises one or more of a single-belt caster, twin-belt caster,
single-roll caster, twin-roll caster, and rotary casters, wherein
the casting assembly component is one or more of a roller, belt,
back-up roll, and block belt, and wherein the microprocessor
executable control system adjusts one or more of the position,
orientation, application force applied to the cast strip, and
pressure applied to the cast strip of or by the casting assembly
component.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefits of U.S.
Provisional Application Ser. No. 62/337,136, filed May 16, 2016, of
the same title, which is incorporated herein by this reference in
its entirety.
FIELD
[0002] The disclosure relates generally to continuous casting and
particularly to automated or partially automated continuous casting
systems.
BACKGROUND
[0003] Continuous casting uses traveling endless molds (e.g.,
rolls, belts, and/or wheels) having zero or substantially zero
relative movement between the mold and casting surfaces. Most
moving molds provide a high cooling rate due to a very small air
gap between the mold and casting surface.
[0004] FIG. 1 shows a prior art block caster 100. In a block
caster, a molten metal poured into a launder 104 is fed from a
headbox or tundish 108 through a ceramic nozzle 112 into the space
between opposing and counter-rotating chains 114a and 114b of metal
chilling blocks 118 traveling on caterpillar-like tracks 122. The
blocks 118 are cooled by chillers 126, which in turn cool and
solidify the melt in the space between the opposing chilling
blocks. Adjacent blocks contact each other to prevent or inhibit
penetration of liquid metal into any inter-block gap to avoid or
minimize the formation of block joints in the surface of the cast
strip 130. The cast strip 130 is pulled out by a withdrawal unit
(not shown) synchronized with the sprocket drive 134 of the blocks.
When adjacent chilling blocks fail to define a planar surface
contacting the cast strip, a surface impression of the joint
between the blocks, known as a block joint, can form on the cast
strip 130 due to relative position or (e.g., the chilling block is
made level before startup but is rarely perfectly flush and there
is movement during caster operation) movement of adjacent blocks
from heating and cooling cycles in response to contact with molten
metal. A typical block joint impression, due to an offset,
irregularity, or step up or down, in adjacent chilling block
surfaces, has a height of up to about 300 microns, more typically
from about 5 to about 100 microns, and more typically from about 10
to about 75 microns above the surrounding surface of the cast strip
and can render the cast strip unsuitable for many applications,
including automotive exterior panels due to post-painting
visibility. As will be appreciated, the cast strip adjacent to the
face of a chilling block (and away from the inter-block joints)
generally has significantly fewer, if any, surface
irregularities.
[0005] FIG. 2 shows a prior art twin-belt caster 200. Molten metal
is fed from the ceramic nozzle 112 through the gap between two
counter-rotating belts 204a and 204b under tension. The belts are
cooled by water jets 208 from a side opposite the surface
contacting the cast strip 130. The cooled belts cool and solidify
the melt between the belts. Back-up rolls 212 maintain a
substantially planar surface of the belt contacting the cast strip
130. The cast strip 130 is pulled out by a withdrawal unit (not
shown) synchronized with the sprocket drive 216 of the blocks. A
common surface defect in cast strip manufactured by belt casters is
an impression of the belt seam. A typical belt seam impression has
a height of up to about 125 microns, more typically from about 5 to
about 100 microns, and more typically from about 10 to about 75
microns above the surrounding surface of the cast strip and can
render the cast strip unsuitable for many applications, including
automotive exterior panels due to post-painting visibility.
[0006] Other continuous casting systems include without limitation
single-roll casters, twin-roll casters, and rotary casters.
[0007] Surface defects in continuously cast strip, such as
impressions left by block joints and belt seams, cause the cast
strip to be unusable in many applications, such as automotive
parts. As a result, more expensive casting techniques, such as
direct chill casting, are used to manufacture metal articles for
these applications.
[0008] There is therefore a need to provide a continuously cast
strip having fewer or no surface defects.
SUMMARY
[0009] These and other needs are addressed by the various aspects,
embodiments, and/or configurations of the present disclosure. The
present disclosure is directed to automated monitoring and/or
adjustment of a casting system or assembly.
[0010] A casting system can include:
[0011] a nozzle to provide a molten metal or metal alloy;
[0012] a casting assembly to cool and mold the molten metal or
metal alloy to form a cast strip;
[0013] a sensor to sense a defect on a surface of the cast strip
surface; and
[0014] a microprocessor executable control system to determine an
adjustment amount and/or direction of a casting assembly component
based on the identified surface defect and at least one of: (a)
provide the adjustment amount and/or direction to an operator for
adjustment of the casting assembly component and (b) command that
the casting assembly component be adjusted by the adjustment amount
and/or direction.
[0015] The casting assembly can include a block caster.
[0016] The casting assembly component can be an adjustment point on
a chilling block.
[0017] The surface defect can be an impression of a block
joint.
[0018] The sensor can be one of a plurality of sensors comprising
first and second sensor sets. Each sensor in the first sensor set
can scan a portion of an upper surface of the cast strip, and each
sensor in the second sensor set can scan a portion of a lower
surface of the cast strip. Each sensor in the first sensor set can
oppose a corresponding sensor in the second sensor set. Each
opposing pair of sensors in the first and second sensor sets can be
in line with a respective adjustment point.
[0019] The sensor can be positioned such that the sensed defect is
caused by the casting assembly component to be adjusted.
[0020] The sensor can be one or more of a laser radar detector, a
mechanical displacement device, an imaging device, an optical 3d
measuring system, or an ultrasound transducer. Commonly, the sensor
is free of contact with the cast strip surface.
[0021] The control system can sense a defect by measuring a
thickness of the cast strip and comparing the measured thickness to
a predetermined thickness for the cast strip.
[0022] The control system can determine the adjustment amount
and/or direction based on a difference between the measured and
predetermined thicknesses.
[0023] The molten metal or alloy can be one or more of manganese, a
manganese alloy, aluminum, an aluminum alloy, copper, a copper
alloy, iron, and an iron alloy.
[0024] The casting system can also include a launder to receive the
molten metal or metal alloy from a furnace and a tundish and/or
headbox to receive the molten metal or metal alloy from the furnace
and provide the melt to the nozzle.
[0025] The casting assembly can alternatively be one or more of a
single-belt caster, twin-belt caster, single-roll caster, twin-roll
caster, and rotary caster.
[0026] The casting assembly component can be one or more of a
roller, belt, back-up roll, and block belt.
[0027] The control system can adjust one or more of the position,
orientation, application force applied to the cast strip, and
pressure applied to the cast strip of or by the casting assembly
component.
[0028] The present disclosure can provide a number of advantages
depending on the particular aspect, embodiment, and/or
configuration. The casting system can identify a cast strip surface
defect and enable automatic or semi-automatic adjustment of one or
more casting system components, during casting system operation, to
inhibit, remove, or reduce the formation of the identified surface
defect in a next casting cycle (e.g., next revolution of a roll,
block or belt caster). This can eliminate not only the need for
manual block adjustment but also for shutting down the casting
system to reset improperly adjusted casting system components. This
has the further benefit of making less expensive continuously cast
strip applicable to a broader variety of applications and
markets.
[0029] These and other advantages will be apparent from the
disclosure.
[0030] As used herein, "at least one", "one or more", and "and/or"
are open-ended expressions that are both conjunctive and
disjunctive in operation. For example, each of the expressions "at
least one of A, B and C", "at least one of A, B, or C", "one or
more of A, B, and C", "one or more of A, B, or C" and "A, B, and/or
C" means A alone, B alone, C alone, A and B together, A and C
together, B and C together, or A, B and C together. When each one
of A, B, and C in the above expressions refers to an element, such
as X, Y, and Z, or class of elements, such as X.sub.1-X.sub.n,
Y.sub.1-Y.sub.m, and Z.sub.1-Z.sub.o, the phrase is intended to
refer to a single element selected from X, Y, and Z, a combination
of elements selected from the same class (e.g., X.sub.1 and
X.sub.2) as well as a combination of elements selected from two or
more classes (e.g., Y.sub.1 and Z.sub.0).
[0031] The term "a" or "an" entity refers to one or more of that
entity. As such, the terms "a" (or "an"), "one or more" and "at
least one" can be used interchangeably herein. It is also to be
noted that the terms "comprising", "including", and "having" can be
used interchangeably.
[0032] "Aluminum alloys" are alloys in which aluminum (Al) is the
predominant metal. The typical alloying elements are copper,
magnesium, manganese, silicon, and zinc.
[0033] The term "automatic" and variations thereof, as used herein,
refers to any process or operation done without material human
input when the process or operation is performed. However, a
process or operation can be automatic, even though performance of
the process or operation uses material or immaterial human input,
if the input is received before performance of the process or
operation. Human input is deemed to be material if such input
influences how the process or operation will be performed. Human
input that consents to the performance of the process or operation
is not deemed to be "material".
[0034] The term "computer-readable medium" as used herein refers to
any storage and/or transmission medium that participate in
providing instructions to a processor for execution. Such a
computer-readable medium is commonly tangible, non-transitory, and
non-transient and can take many forms, including but not limited
to, non-volatile media, volatile media, and transmission media and
includes without limitation random access memory ("RAM"), read only
memory ("ROM"), and the like. Non-volatile media includes, for
example, NVRAM, or magnetic or optical disks. Volatile media
includes dynamic memory, such as main memory. Common forms of
computer-readable media include, for example, a floppy disk
(including without limitation a Bernoulli cartridge, ZIP drive, and
JAZ drive), a flexible disk, hard disk, magnetic tape or cassettes,
or any other magnetic medium, magneto-optical medium, a digital
video disk (such as CD-ROM), any other optical medium, punch cards,
paper tape, any other physical medium with patterns of holes, a
RAM, a PROM, and EPROM, a FLASH-EPROM, a solid state medium like a
memory card, any other memory chip or cartridge, a carrier wave as
described hereinafter, or any other medium from which a computer
can read. A digital file attachment to e-mail or other
self-contained information archive or set of archives is considered
a distribution medium equivalent to a tangible storage medium. When
the computer-readable media is configured as a database, it is to
be understood that the database may be any type of database, such
as relational, hierarchical, object-oriented, and/or the like.
Accordingly, the disclosure is considered to include a tangible
storage medium or distribution medium and prior art-recognized
equivalents and successor media, in which the software
implementations of the present disclosure are stored.
Computer-readable storage medium commonly excludes transient
storage media, particularly electrical, magnetic, electromagnetic,
optical, magneto-optical signals.
[0035] The term "continuous casting" or "strand casting" refers to
the process whereby molten metal is solidified into a
"semifinished" billet, bloom, or slab for subsequent rolling in the
finishing mills. Continuous casting is often used to cast aluminum,
magnesium, and copper alloys and steel.
[0036] The terms "determine", "calculate" and "compute," and
variations thereof, as used herein, are used interchangeably and
include any type of methodology, process, mathematical operation,
algorithm, or technique.
[0037] The term "means" as used herein shall be given its broadest
possible interpretation in accordance with 35 U.S.C., Section 112,
Paragraph 6. Accordingly, a claim incorporating the term "means"
shall cover all structures, materials, or acts set forth herein,
and all of the equivalents thereof. Further, the structures,
materials or acts and the equivalents thereof shall include all
those described in the summary, brief description of the drawings,
detailed description, abstract, and claims themselves.
[0038] The term "module" as used herein refers to any known or
later developed hardware, software, firmware, artificial
intelligence, fuzzy logic, or combination of hardware and software
that is capable of performing the functionality associated with
that element.
[0039] Unless otherwise noted, all component or composition levels
are in reference to the active portion of that component or
composition and are exclusive of impurities, for example, residual
solvents or by-products, which may be present in commercially
available sources of such components or compositions.
[0040] All percentages and ratios are calculated by total
composition weight, unless indicated otherwise.
[0041] Unless otherwise noted, all component or composition levels
are in reference to the active portion of that component or
composition and are exclusive of impurities, for example, residual
solvents or by-products, which may be present in commercially
available sources of such components or compositions.
[0042] All percentages and ratios are calculated by total
composition weight, unless indicated otherwise. The preceding is a
simplified summary of the disclosure to provide an understanding of
some aspects of the disclosure. This summary is neither an
extensive nor exhaustive overview of the disclosure and its various
aspects, embodiments, and/or configurations. It is intended neither
to identify key or critical elements of the disclosure nor to
delineate the scope of the disclosure but to present selected
concepts of the disclosure in a simplified form as an introduction
to the more detailed description presented below. As will be
appreciated, other aspects, embodiments, and/or configurations of
the disclosure are possible utilizing, alone or in combination, one
or more of the features set forth above or described in detail
below. Also, while the disclosure is presented in terms of
exemplary embodiments, it should be appreciated that individual
aspects of the disclosure can be separately claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] The accompanying drawings are incorporated into and form a
part of the specification to illustrate several examples of the
present disclosure. These drawings, together with the description,
explain the principles of the disclosure. The drawings simply
illustrate preferred and alternative examples of how the disclosure
can be made and used and are not to be construed as limiting the
disclosure to only the illustrated and described examples. Further
features and advantages will become apparent from the following,
more detailed, description of the various aspects, embodiments, and
configurations of the disclosure, as illustrated by the drawings
referenced below.
[0044] FIG. 1 depicts a prior art block casting system;
[0045] FIG. 2 depicts a prior art twin-belt casting system;
[0046] FIG. 3 depicts a partial top view of a block casting system
according to an embodiment of this disclosure;
[0047] FIG. 4 depicts a partial side view of a block casting system
according to an embodiment of this disclosure;
[0048] FIG. 5A is a top view of a chilling block according to an
embodiment;
[0049] FIG. 5B is a side view of a chilling block according to an
embodiment;
[0050] FIG. 6 is a flow chart of control logic according to an
embodiment;
[0051] FIG. 7 graphically depicts sensor feedback; and
[0052] FIG. 8 graphically depicts sensor feedback.
DETAILED DESCRIPTION
[0053] FIGS. 3 and 4 depict an embodiment of a block casting system
300 according to this disclosure. The block casting system has
upper and lower sets 304a and 304b of chilling blocks 316 to cool
and solidify the molten metal into a cast strip 130, plural sensors
308 located above and below the cast strip 130 to detect surface
defects, such as block joint impressions caused by inter-block
joints 320 (the solid line refers to the joint 320 between adjacent
chilling blocks 316 in upper set 304a and dashed lines refer to the
joints 320 between adjacent chilling blocks in lower set 304b) and
belt seams, and an adjustment control module 312, in communication
by control lines 324 with the sensors and adjustment components in
the chilling blocks 316, to receive measurements and provide user
recommendations or automatic commands to adjust the blocks 316
appropriately to substantially minimize or inhibit formation of
surface defects.
[0054] Surface defects removed, inhibited, or otherwise reduced in
frequency by the block casting system 300 can vary depending on the
casting technology employed. Surface defects in continuously cast
strip include, for example, impressions left by block joints and
belt seams, streaks, drag marks, protrusions, channels, valleys,
crystallites, films (such oxide films), impurities, or combinations
thereof. While not wanting to be limited by theory, the defects can
be caused by one or more of the rollers, belts, and blocks of the
caster and can be addressed by adjusting one or more of the
position, orientation, application force or pressure (applied to
the cast strip), and the like of the roller, belt, or block.
[0055] There a number of examples of surface defects that can be
addressed by the control system. In a belt caster, there can be
repeating defects in the belt thickness due to welding or coating
thickness and dimension defects on any of the back-up rolls behind
the belt. Flat spots can occur when the caster is stopped with
molten metal in it, the back-up rolls can be machined out of round
or eccentricities can exist between the rolling center and the
surface of the roll against which the belt rests. In these cases,
the roll would have dimensional adjustments at the bearings. The
rolls can also be bent, which can be corrected with roll bending.
The same can be true of a roll caster, with eccentricities, flat
spots, and coating thickness variations. A difference is that the
point of adjustment or adjustment point would be at the bearing
points with possibly bending at the same place. The control system
can adjust the roll across the face. There are sensors that are
made up of a series of rings that measure tight spots in the cast
strip, slab, or sheet. A roll can be made using actuators in place
of sensors to make changes in the geometry of the mold of a roll
caster. The roll can include a series of rings on the center shaft
with adjustments from the shaft access to accommodate thickness
variations across the face of the cast surface due to a variation
in roll geometry or even metal temperature variations causing
dimensional variation in the slab thickness.
[0056] Referring to FIGS. 3-4 and 5A and 5B, each chilling block
316 in the upper and lower sets 304a and 304b of chilling blocks is
positioned on one of the opposing sides of the cast strip 130 and
includes multiple adjustment points or adjustment devices 328
(hereinafter "adjustment points"), typically located at or near
each joint 320. Although the adjustment points 328 can be any
device able to move the chilling block upwardly and/or downwardly
at the adjustment point's respective location (as shown by the
arrows in FIGS. 5A and 5B), examples of adjustment points 328
include coarse and/or fine adjustment screws, differential
adjusters, sub-micron adjustors, hydraulic actuators, and other
adjustment mechanisms.
[0057] As shown in FIGS. 5A and 5B, the adjustment points 328 can
be distributed at selected locations in a matrix or grid pattern.
Adjustment points 328a-f are laid out along line 500 and adjustment
points 328g-l along parallel line 504. Pairs of adjustment points
are further laid out along lines orthogonal to parallel lines 500
and 504, specifically adjustment points 329a and g are laid out
along line 508, adjustment points 329b and h are laid out along
line 512, adjustment points 329c and i are laid out along line 516,
adjustment points 329d and j are laid out along line 520,
adjustment points 329e and h are laid out along line 524, and
adjustment points 329f and i are laid out along line 528.
[0058] To enable the control system 312 to address independently
each adjustment point, each adjustment point is assigned a unique
identifier relative to the other adjustment points. Although any
type of identifier can be employed, the identifier in one
embodiment has a first unique identifier "X" corresponding to an
identifier of the upper or lower set of chilling blocks of which
the selected chilling block 316 is a member, a second identifier
"Y" (which may be non-unique relative to another chilling block in
the other set of chilling blocks but is unique within the set of
chilling blocks of which the selected chilling block is a member)
corresponding to an identifier of the particular chilling block
adjusted by the selected adjustment point, and a third identifier
"Z" (which may be non-unique relative to another adjustment point
in another chilling block in the upper or lower sets of chilling
blocks 304a and 304b but is unique within the corresponding
chilling block 316 on which the selected adjustment point is
located) is an identifier corresponding to the selected adjustment
point.
[0059] The sensors 308 can be any device able to detect surface
irregularities or defects, such as block joint impressions, in the
upper and/or lower surfaces of the cast strip 130. Examples include
a laser radar detector (which uses a laser beam 350 to determine
the distance to the cast strip surface), mechanical displacement
device (which measures the vertical variations in travel or
movement of a wheel or other contact device with the cast strip
surface), imaging device (which uses image processing to identify
surface defects and other variations in cast strip surface
topology, such as image processing based on the cast strip surface
images captured by still pictures or video images captured as
described in U.S. Pat. No. 4,539,561 (which is incorporated herein
by this reference)), optical 3d measuring system (which uses
triangulation to determine the spatial dimensions and the geometry
of the cast strip surface), and ultrasound transducer (which uses
an ultrasound transducer to emit ultrasonic energy and ultrasonic
time-of-flight methods to measure distance from the sensor to the
cast strip surface). Laser radar, for example, can operate on the
time of flight principle by sending a laser pulse in a narrow beam
towards the cast strip surface and measuring the time taken by the
pulse to be reflected off the target cast strip surface and
returned to the sender. Other laser radar distance measuring
technologies include multiple frequency phase-shift (which uses an
intensity modulated beam to measure the phase shift of multiple
frequencies on reflection from the cast strip surface and then
solves various simultaneous equations to yield a final distance
measure from the sensor to the cast strip surface), frequency
modulation (which use modulated laser beams, for example, with a
repetitive linear frequency ramp by which the distance to be
measured from the sensor to the cast strip surface is translated
into a frequency offset) and interferometry (which measures changes
in distance between the sensor and cast strip surface rather than
absolute distances). Due to the high temperatures of the cast
strip, non-contact sensors, such as laser radar, imaging devices,
optical 3d measuring systems, and ultrasound systems, are generally
employed.
[0060] As in the case of the adjustment points 328, each sensor has
a unique (relative to the other sensors) sensor identifier. The
sensor identifier can be as simple as a combination of a generic
sensor identifier (indicating that the signal originates at a
sensor) and a number of the sensor (indicating that sensor 1 for
example originated the signal). In another example, the sensor
identifier can be a combination of a first indicator (indicating
whether the sensor is located above or below the cast slab 130) and
a second identifier indicating which sensor of the corresponding
set of upper or lower sensors originated the signal).
[0061] The geometry of the block casting system 300 can be
important. Referring to FIG. 3, the centers of the adjustment
points and centers of the corresponding pair of upper and lower
sensors are commonly located in or along a common plane. By way of
example, as shown in FIG. 3 the centers of the top row of
adjustment points 328 and upper and lower sensors 308 can lie in
plane 360, the centers of the next row of adjustment points 328 and
upper and lower sensors 308 can lie in plane 364, the centers of
the next row of adjustment points 328 and upper and lower sensors
308 can lie in plane 368, the centers of the next row of adjustment
points 328 and upper and lower sensors 308 can lie in plane 372,
the centers of the next row of adjustment points 328 and upper and
lower sensors 308 can lie in plane 376, and the centers of the next
row of adjustment points 328 and upper and lower sensors 308 can
lie in plane 378. The centers of the upper and lower sets of
sensors 308 can lie in a common plane 382.
[0062] The distance 388 between an adjustment zone 392 and
measurement zone 396 can be selected such that the surface portion
of the cast strip in the measurement zone at any point in time was
molded by and in contact with the inter-block joint 320 of adjacent
chilling blocks 318 (or chilling block 318 portion) currently in
the adjustment zone. In this manner, the adjacent sets of
adjustment points on either side of the inter-block joint 320 can
be adjusted to remove any block joint impression in the cast strip
surface 130 detected by the sensors. Accordingly, the distance 388
is typically a function of one or more of the speed of displacement
of the cast strip 130, the rate of rotation of the sprocket drive
216, chilling block 316 width, and the number of chilling blocks
316 in each of the upper and lower sets of chilling blocks 304a and
304b.
[0063] Prior to discussing the operation of the control system 312,
it is important to understand the operation of the block casting
system 300 in manufacturing cast strip 130. As can be seen from
FIG. 3, the inter-block joints 320 of the blocks in contact with
the upper surface of the cast strip 130 and adjustment points are
offset in the direction of cast strip travel from the inter-block
joints 320 and adjustment points of the blocks in contact with the
lower surface of the cast strip 130. In this manner, the cast strip
surface potentially containing a block joint impression from an
inter-block joint in the adjustment zone alternates between the
upper and lower cast strip surfaces as the cast strip moves through
the measurement zone 396. As can be further seen by the arrows 398
and 399, the upper and lower chilling blocks 316 and inter-block
joints 320 move in a common direction when in contact with the cast
strip.
[0064] The operation of the control system 312 will now be
discussed with reference to FIG. 6. The discussion assumes that the
block casting system 300 is operating to produce cast strip
130.
[0065] In step 600, the control system detects a set of adjustment
points for a chilling block and/or inter-block joint entering the
adjustment zone (or a welded belt seam entering the adjustment zone
in the case of a belt caster). This can be determined in many ways.
In one technique, a position of a selected chilling block and/or
inter-block joint (or a welded belt seam entering the zone in the
case of a belt caster) is synchronized in computer readable memory
with movement of one or both of the upper and lower sets of
chilling blocks 304a and 304b (or the upper and lower belts in the
case of a belt caster). Based on this monitored location, the
locations of the other chilling block and/or inter-block joints (or
the welded belt seam entering the adjustment zone in the case of a
belt caster) are readily determined (as the chilling blocks have
substantially uniform width and/or are in a predictable constant
sequence as the supporting belt moves through each revolution). In
another technique, the control system 312, in the measurement zone
396, identifies a surface defect, such as a block joint impression
or belt seam impression, and identifies one or more selected
adjustment points (or other casting component) for possible
adjustment.
[0066] In step 602, the control system 312 selects a sensor set
corresponding to one or more selected adjustment point(s) (such as
adjacent and opposing adjustment point(s) on either side of a
selected inter-block joint (or other casting component) entering,
departing, or currently in the adjustment zone 392). The sensor
set, for example, when the selected adjustment point(s) is/are
adjustment point 328a and 328b (or other casting component) is
sensor 308a in the upper set of sensors 353 and the sensor (not
shown) positioned directly below sensor 308a in the lower set of
sensors 355.
[0067] The role of each sensor in the selected set can vary
depending on the location of the surface defect relative to the
sensor position. When the surface defect is on the upper cast strip
surface, a first sensor (typically the upper sensor) is selected as
the "zero" or reference point and the opposing second sensor
(typically the lower sensor) is selected as the thickness measuring
sensor. When the surface defect is on the lower cast strip surface,
the second sensor (typically the lower sensor) is selected as the
"zero" or reference point and the opposing first sensor (typically
the upper sensor) is selected as the thickness measuring
sensor.
[0068] In step 604, the control system 312 receives measurements
from the selected sensor set and determines a thickness of the cast
strip proximal to the selected sensor set. The control system 312,
as will be appreciated, can query the selected sensor set for a set
of readings or receive multiple sets of sensor readings from all
sensor sets and select the appropriate sets of readings, based on
the identities of the source sensor set. The selected set of sensor
readings can enable the control system 312 to determine the
thickness of the cast strip at the point of measurement.
[0069] In step 608, the control system 312 compares the measured
thickness to a predetermined thickness for the cast strip 130 and,
in decision diamond 612, determines whether or not to adjust the
selected adjustment point(s) (or other casting component). When an
absolute value of a difference in the thickness from the
predetermined thickness is at least a predetermined threshold, the
control system 312 proceeds to step 616. Alternatively, the control
system 312 can determine a difference of the measured thickness
from a thickness measured by a prior set of sensor readings from
the selected sensor set for an adjustment point (or other casting
component) in the same plane and/or a thickness measured by one or
more adjacent sensor set(s) in one or more adjacent plane(s). When
an absolute value of a delta between the determined difference and
a predetermined difference is at least a predetermined threshold,
the control system 312 proceeds to step 616.
[0070] In step 616, the control system 312 determines an adjustment
amount and direction (e.g., up or down (to increase or decrease
cast strip thickness as appropriate) and either commands the
selected adjustment point(s) (or other casting component) to be
adjusted (by a control signal addressed to the unique identifier of
the casting component) to the determined adjustment amount and
direction or recommends to a human user the adjustment amount and
direction for manual adjustment of the casting component by the
user (such as by the user pressing an actuator to cause movement up
or down of the block in response to adjustment point activation).
When automatic adjustment is performed, one or both of the opposing
adjustment points on either side of the inter-block joint can be
adjusted in a manner to maintain the cast strip thickness at and on
either side of the inter-block joint 320 or other casting defect at
or near the predetermined thickness. The target adjustment amount
may be equivalent to the difference between the measured thickness
and predetermined thickness or a fraction or percentage thereof.
The adjustment points (or other casting component) can thus be
adjusted in the same direction and by the same amount or by
different amounts that sum up to the desired adjustment amount.
Alternatively, the cast strip thickness on either side of the
inter-block joint (or other casting component) can be measured and
each adjustment point adjusted to produce the predetermined
thickness at its respective location.
[0071] After step 616 or when no adjustment is required, the
control system, in decision diamond 620 determines whether there is
an adjustment point or set of adjustment points (or other casting
component) in the adjustment zone. For example, when an inter-block
joint is in the adjustment zone the preceding step must be repeated
for each adjustment point adjacent to the inter-block joint.
[0072] When a further adjustment point(s) for the inter-block joint
remains to be considered for adjustment, the control system returns
to step 602.
[0073] When no further adjustment points for the inter-block joint
remain to be considered for adjustment, the control system returns
to step 600.
[0074] The disclosure can apply to detection of and/or continuous
casting component adjustment due to surface defects other than
impressions left by block joints. For example, the disclosure can
apply to any of the surface defects discussed above.
[0075] The disclosure can apply to automatic adjustment of
components in other continuous casting techniques, such as
twin-belt casters, single-roll casters, twin-roll casters, and
rotary casters. In belt casters, for instance, the casting
component to be adjusted can be the back-up rolls 212 so as to
maintain a substantially planar surface of the belt contacting the
cast strip 130.
[0076] The disclosure can apply to a wide variety of alloys, such
as aluminum, aluminum alloys, magnesium, magnesium alloys, copper,
copper alloys, and steel. Aluminum alloys, for example, include AA
1XXX, 2XXX, 3XXX, 4XXX, 5XXX, 6XXX, and 7XXX.
[0077] A 1000 series-based aluminum alloy typically has the
following composition:
[0078] (i) from about 0.05 to about 0.20% by weight magnesium;
[0079] (ii) from about 0.01 to about 0.20% by weight manganese;
[0080] (iii) from about 0.01 to about 0.25% by weight copper;
[0081] (iv) from about 0.001 to about 0.08% by weight iron;
[0082] (v) from about 0.001 to about 0.02% by weight silicon;
[0083] (vi) from about 0.001 to about 0.095% by weight
chromium;
[0084] (vii) from about 0.01 to about 0.45% by weight zinc;
[0085] (viii) from about 0.001 to about 0.045% by weight
nickel;
[0086] (ix) from about 0.01 to about 0.175% by weight titanium;
and
[0087] (x) no more than about 0.05 wt. % other impurities.
[0088] A 2000 series-based aluminum alloy typically has the
following composition:
[0089] (i) from about 0.02 to about 1.8% by weight magnesium;
[0090] (ii) from about 0.1 to about 1.2% by weight manganese;
[0091] (iii) from about 1.8 to about 6.8% by weight copper;
[0092] (iv) from about 0.07 to about 1.0% by weight iron;
[0093] (v) from about 0.05 to about 0.5% by weight silicon;
[0094] (vi) from about 0.05 to about 0.8% by weight chromium;
[0095] (vii) from about 0.05 to about 1.4% by weight zinc;
[0096] (viii) from about 0.01 to about 0.2% by weight nickel;
[0097] (ix) from about 0.01 to about 0.175% by weight titanium;
and
[0098] (x) no more than about 0.05 wt. % other impurities.
[0099] A 3000 series-based aluminum alloy typically has the
following composition:
[0100] (i) from about 0.01 to about 1.3% by weight magnesium;
[0101] (ii) from about 0.01 to about 1.3% by weight manganese;
[0102] (iii) from about 0.01 to about 0.3% by weight copper;
[0103] (iv) from about 0.1 to about 0.7% by weight iron;
[0104] (v) from about 0.10 to about 1.7% by weight silicon;
[0105] (vi) from about 0.01 to about 0.35% by weight chromium;
[0106] (vii) from about 0.001 to about 0.09% by weight zinc;
[0107] (viii) from about 0.001 to about 0.09% by weight nickel;
[0108] (ix) from about 0.001 to about 0.09% by weight titanium;
and
[0109] (x) no more than about 0.15 wt. % other impurities.
[0110] A 4000 series-based aluminum alloy typically has the
following composition:
[0111] (i) from about 0.05 to about 2.0% by weight magnesium;
[0112] (ii) from about 0.05 to about 1.5% by weight manganese;
[0113] (iii) from about 0.05 to about 5.0% by weight copper;
[0114] (iv) from about 0.09 to about 1.0% by weight iron;
[0115] (v) from about 0.6 to about 13.5% by weight silicon;
[0116] (vi) from about 0.05 to about 0.25% by weight chromium;
[0117] (vii) from about 0.05 to about 1.3% by weight zinc;
[0118] (viii) from about 0 to about 2.2% by weight nickel;
[0119] (ix) from about 0.5 to about 0.3% by weight titanium;
and
[0120] (x) no more than about 0.05 wt. % other impurities.
[0121] A 5000 series-based aluminum alloy useful for producing tab
or end stock has the following composition:
[0122] (i) from about 2.0 to about 5.0% by weight magnesium;
[0123] (ii) from about 0.10 to about 1.25% by weight manganese;
[0124] (iii) from about 0.001 to about 0.45% by weight copper;
[0125] (iv) from about 0.1 to about 0.85% by weight iron;
[0126] (v) from about 0.1 to about 1.3% by weight silicon;
[0127] (vi) from about 0.01 to about 0.3% by weight chromium;
[0128] (vii) from about 0.75 to about 2.7% by weight zinc;
[0129] (viii) from about 0.001 to about 0.045% by weight
nickel;
[0130] (ix) from about 0.01 to about 0.175% by weight titanium;
and
[0131] (x) no more than about 0.15 wt. % other impurities.
[0132] A 6000 series-based aluminum alloy typically has the
following composition:
[0133] (i) from about 0.2 to about 3.0% by weight magnesium;
[0134] (ii) from about 0.05 to about 1.0% by weight manganese;
[0135] (iii) from about 0.05 to about 0.9% by weight copper;
[0136] (iv) from about 0.1 to about 0.8% by weight iron;
[0137] (v) from about 0.3 to about 1.5% by weight silicon;
[0138] (vi) from about 0.03 to about 0.35% by weight chromium;
[0139] (vii) from about 0.05 to about 1.0% by weight zinc;
[0140] (viii) from about 0 to about 0.2% by weight nickel;
[0141] (ix) from about 0 to about 0.2% by weight titanium; and
[0142] (x) no more than about 0.05 wt. % other impurities.
[0143] A 7000 series-based aluminum alloy typically has the
following composition:
[0144] (i) from about 0.1 to about 3.3% by weight magnesium;
[0145] (ii) from about 0.04 to about 0.8% by weight manganese;
[0146] (iii) from about 0.1 to about 2.8% by weight copper;
[0147] (iv) from about 0 to about 0.5% by weight iron;
[0148] (v) from about 0.05 to about 0.4% by weight silicon;
[0149] (vi) from about 0.04 to about 0.28% by weight chromium;
[0150] (vii) from about 0.8 to about 12% by weight zinc;
[0151] (viii) from about 0 to about 0.03% by weight nickel;
[0152] (ix) from about 0.03 to about 0.2% by weight titanium;
and
[0153] (x) no more than about 0.05 wt. % other impurities.
[0154] More specifically, the cast strip can be comprise an
aluminum alloy selected from the group of consisting of aluminum
alloys 1050, 1060, 1100, 1199, 2014, 2024, 2219, 303, 3004, 3102,
4041, 5005, 5052, 5083, 5086, 5154, 5182, 5356, 5454, 5456, 5754,
6005, 6005A, 6014, 6022, 6060, 6061, 6063, 6066, 6070, 6082, 6105,
6111, 6016, 6162, 6262, 6351, 6463, 7005, 7022, 7050, 7068, 7072,
7075, 7079, 7116, 7129, and 7178. In some embodiments, the cast
strip can be comprise an aluminum alloy suitable for aircraft or
aerospace structures selected from the group of consisting of
aluminum alloys 2024, 5052, 6061, 6063, 7050, 7068, and 7075. In
some embodiments, the cast strip can be comprise an aluminum alloy
suitable for marine structures selected from the group of
consisting of aluminum alloys 5052, 5059, 5083, 5086, 6061, and
6063. In some embodiments, the cast strip can comprise an aluminum
alloy suitable for automotive structures selected from the group of
consisting of aluminum alloys 2008, 2036, 5083, 5456, 5754, 6016,
and 6111.
EXPERIMENTAL
[0155] The following examples are provided to illustrate certain
embodiments of the invention and are not to be construed as
limitations on the invention, as set forth in the appended claims.
All parts and percentages are by weight unless otherwise
specified.
[0156] Prior to contact with a molten aluminum alloy, the chilling
blocks of the block caster were carefully adjusted mechanically to
form a level surface for contact with the cast strip and then
casting commenced.
[0157] The laser scanning system was initially set up and measured
the geometry of the slab produced by the manually adjusted block
caster. As the cast strip was removed from the block caster, laser
radar from the laser scanning measurement system revealed
variations and fluctuations in the planarity of the cast strip due
to contact with the molten aluminum alloy. This geometry is
represented in FIGS. 7 and 8. The before and after pictures (FIGS.
8 and 7 respectively) show the top and bottom of the aluminum cast
strip or slab. The coordinates are in centimeters. A careful
inspection can reveal all 32 top and 32 bottom blocks of the block
caster. The bottom surface 804 shows what the surface would look
like if one could look down from within the cast strip. As can be
seen from the opposite side of the surface, it appears to be
inverted. The high points shown are really low points when looking
from underneath the sheet. The before view (FIG. 8) is the sheet
before the adjustment of the caster blocks.
[0158] FIGS. 7 and 8 depict irregularities or defects in the
opposing upper and lower surfaces 700 and 704 (FIGS. 7) and 800 and
804 (FIG. 8) of a cast strip from the block caster. The cast strip
130 has multiple surface defects along its length. Some of the
surface defects are higher above the adjacent surface than others.
By way of example and as can be seen by the variations in color
(which variations represent the elevation relative to a reference
plane), defects 708 correspond to impressions of elevated
inter-block joints while other lower surfaces 712 correspond to
planar faces of chilling blocks. The thickness "T" between the
opposing surfaces is seen to vary in response to the occurrence of
surface defects.
[0159] Thus, the after view (FIG. 7) is the sheet after the
adjustment of the caster blocks. The after view shows an overall
smoother and more planar strip on both the upper and lower strip
surfaces compared to the before view (FIG. 8). As can be seen from
FIG. 8, the locations of the inter-block joints 708 are lower in
elevation relative to the surrounding surface compared to the
inter-block joints 708 of FIG. 7.
[0160] As can be seen, laser radar can be used to identify
impressions of block joints where slab thickness is thicker or
thinner than the target stab thickness.
[0161] A significant improvement in geometry of the slab after the
blocks were adjusted manually to be closer to flush based on the
before view was observed such that the cast strip surface had fewer
significant variations in thickness. The caster operated normally
so the allowance on the adjustment to flush was loosened.
[0162] The experiment further revealed the substantial movement of
the chilling blocks during casting notwithstanding the extreme care
taken before casting commenced to ensure planarity of surfaces of
adjacent chilling blocks. Although the blocks were adjusted to very
tight tolerances, the blocks moved substantially during startup to
a much greater degree than previously thought.
[0163] Based on the experiment, the feasibility of a closed loop
block height control was established. A laser measuring device
properly installed to observe the cast strip can provide slab
thickness consistency and enable dynamic adjustment of block height
even while the caster is running or operating. Some block casters
have adjustment devices or adjusters located at the interface
between adjacent blocks which would be used to effect
computer-controlled adjustments. Additionally, block adjustments
from side-to-side may also be computer-controlled. This
configuration can provide block position adjustments on fore and
aft sides of the block and across the width of the block at about
10 inch increments.
[0164] Examples of the processors as described herein may include,
but are not limited to, at least one of Qualcomm.RTM.
Snapdragon.RTM. 800 and 801, Qualcomm.RTM. Snapdragon.RTM. 610 and
615 with 4G LTE Integration and 64-bit computing, Apple.RTM. A7
processor with 64-bit architecture, Apple.RTM. M7 motion
coprocessors, Samsung.RTM. Exynos.RTM. series, the Intel.RTM.
Core.TM. family of processors, the Intel.RTM. Xeon.RTM. family of
processors, the Intel.RTM. Atom.TM. family of processors, the Intel
Itanium.RTM. family of processors, Intel.RTM. Core.RTM. i5-4670K
and i7-4770K 22 nm Haswell, Intel.RTM. Core.RTM. i5-3570K 22 nm Ivy
Bridge, the AMD.RTM. FX.TM. family of processors, AMD.RTM. FX-4300,
FX-6300, and FX-8350 32 nm Vishera, AMD.RTM. Kaveri processors,
Texas Instruments.RTM. Jacinto C6000.TM. automotive infotainment
processors, Texas Instruments.RTM. OMAP.TM. automotive-grade mobile
processors, ARM.RTM. Cortex.TM.-M processors, ARM.RTM. Cortex-A and
ARM926EJ-S.TM. processors, other industry-equivalent processors,
and may perform computational functions using any known or
future-developed standard, instruction set, libraries, and/or
architecture.
[0165] The exemplary systems and methods of this disclosure have
been described in relation to a block casting system. However, to
avoid unnecessarily obscuring the present disclosure, the preceding
description omits a number of known structures and devices. This
omission is not to be construed as a limitation of the scopes of
the claims. Specific details are set forth to provide an
understanding of the present disclosure. It should however be
appreciated that the present disclosure may be practiced in a
variety of ways beyond the specific detail set forth herein.
[0166] Furthermore, while the exemplary aspects, embodiments,
and/or configurations illustrated herein show the various
components of the system collocated, certain components of the
system can be located remotely, at distant portions of a
distributed network, such as a LAN and/or the Internet, or within a
dedicated system. Thus, it should be appreciated, that the
components of the system can be combined in to one or more devices
or collocated on a particular node of a distributed network, such
as an analog and/or digital telecommunications network, a
packet-switch network, or a circuit-switched network. It will be
appreciated from the preceding description, and for reasons of
computational efficiency, that the components of the system can be
arranged at any location within a distributed network of components
without affecting the operation of the system. Similarly, one or
more functional portions of the system could be distributed between
multiple device(s).
[0167] Furthermore, it should be appreciated that the various links
connecting the elements can be wired or wireless links, or any
combination thereof, or any other known or later developed
element(s) that is capable of supplying and/or communicating data
to and from the connected elements. These wired or wireless links
can also be secure links and may be capable of communicating
encrypted information. Transmission media used as links, for
example, can be any suitable carrier for electrical signals,
including coaxial cables, copper wire and fiber optics, and may
take the form of acoustic or light waves, such as those generated
during radio-wave and infra-red data communications.
[0168] Also, while the flowcharts have been discussed and
illustrated in relation to a particular sequence of events, it
should be appreciated that changes, additions, and omissions to
this sequence can occur without materially affecting the operation
of the disclosed embodiments, configuration, and aspects.
[0169] A number of variations and modifications of the disclosure
can be used. It would be possible to provide for some features of
the disclosure without providing others.
[0170] For example in one alternative embodiment, the control
system is embodied as an artificially intelligent algorithm able to
modify its behavior based on repeated observations, such as using
fuzzy logic, expert systems, neural networks, and robotics.
Artificial intelligence can observe the effects of adjusting
adjustment points over time and modify to what degree and how
adjustments are made to adapt to changes in behavior of the casting
system. For example, blocks wear, thermal conditions change, alloy
compositions change, and the like.
[0171] For example, another embodiment of the casting system is
shown in the Attachment, which is incorporated herein by this
reference.
[0172] In yet another embodiment, the systems and methods of this
disclosure can be implemented in conjunction with a special purpose
computer, a programmed microprocessor or microcontroller and
peripheral integrated circuit element(s), an ASIC or other
integrated circuit, a digital signal processor, a hard-wired
electronic or logic circuit such as discrete element circuit, a
programmable logic device or gate array such as PLD, PLA, FPGA,
PAL, special purpose computer, any comparable means, or the like.
In general, any device(s) or means capable of implementing the
methodology illustrated herein can be used to implement the various
aspects of this disclosure. Exemplary hardware that can be used for
the disclosed embodiments, configurations and aspects includes
computers, handheld devices, telephones (e.g., cellular, Internet
enabled, digital, analog, hybrids, and others), and other hardware
known in the art. Some of these devices include processors (e.g., a
single or multiple microprocessors), memory, nonvolatile storage,
input devices, and output devices. Furthermore, alternative
software implementations including, but not limited to, distributed
processing or component/object distributed processing, parallel
processing, or virtual machine processing can also be constructed
to implement the methods described herein.
[0173] In yet another embodiment, the disclosed methods may be
readily implemented in conjunction with software using object or
object-oriented software development environments that provide
portable source code that can be used on a variety of computer or
workstation platforms. Alternatively, the disclosed system may be
implemented partially or fully in hardware using standard logic
circuits or VLSI design. Whether software or hardware is used to
implement the systems in accordance with this disclosure is
dependent on the speed and/or efficiency requirements of the
system, the particular function, and the particular software or
hardware systems or microprocessor or microcomputer systems being
utilized.
[0174] In yet another embodiment, the disclosed methods may be
partially implemented in software that can be stored on a storage
medium, executed on programmed general-purpose computer with the
cooperation of a controller and memory, a special purpose computer,
a microprocessor, or the like. In these instances, the systems and
methods of this disclosure can be implemented as program embedded
on personal computer such as an applet, JAVA.RTM. or CGI script, as
a resource residing on a server or computer workstation, as a
routine embedded in a dedicated measurement system, system
component, or the like. The system can also be implemented by
physically incorporating the system and/or method into a software
and/or hardware system.
[0175] Although the present disclosure describes components and
functions implemented in the aspects, embodiments, and/or
configurations with reference to particular standards and
protocols, the aspects, embodiments, and/or configurations are not
limited to such standards and protocols. Other similar standards
and protocols not mentioned herein are in existence and are
considered to be included in the present disclosure. Moreover, the
standards and protocols mentioned herein and other similar
standards and protocols not mentioned herein are periodically
superseded by faster or more effective equivalents having
essentially the same functions. Such replacement standards and
protocols having the same functions are considered equivalents
included in the present disclosure.
[0176] The present disclosure, in various aspects, embodiments,
and/or configurations, includes components, methods, processes,
systems and/or apparatus substantially as depicted and described
herein, including various aspects, embodiments, configurations
embodiments, subcombinations, and/or subsets thereof. Those of
skill in the art will understand how to make and use the disclosed
aspects, embodiments, and/or configurations after understanding the
present disclosure. The present disclosure, in various aspects,
embodiments, and/or configurations, includes providing devices and
processes in the absence of items not depicted and/or described
herein or in various aspects, embodiments, and/or configurations
hereof, including in the absence of such items as may have been
used in previous devices or processes, e.g., for improving
performance, achieving ease and\or reducing cost of
implementation.
[0177] The foregoing discussion has been presented for purposes of
illustration and description. The foregoing is not intended to
limit the disclosure to the form or forms disclosed herein. In the
foregoing Detailed Description for example, various features of the
disclosure are grouped together in one or more aspects,
embodiments, and/or configurations for the purpose of streamlining
the disclosure. The features of the aspects, embodiments, and/or
configurations of the disclosure may be combined in alternate
aspects, embodiments, and/or configurations other than those
discussed above. This method of disclosure is not to be interpreted
as reflecting an intention that the claims require more features
than are expressly recited in each claim. Rather, as the following
claims reflect, inventive aspects lie in less than all features of
a single foregoing disclosed aspect, embodiment, and/or
configuration. Thus, the following claims are hereby incorporated
into this Detailed Description, with each claim standing on its own
as a separate preferred embodiment of the disclosure.
[0178] Moreover, though the description has included description of
one or more aspects, embodiments, and/or configurations and certain
variations and modifications, other variations, combinations, and
modifications are within the scope of the disclosure, e.g., as may
be within the skill and knowledge of those in the art, after
understanding the present disclosure. It is intended to obtain
rights which include alternative aspects, embodiments, and/or
configurations to the extent permitted, including alternate,
interchangeable and/or equivalent structures, functions, ranges or
steps to those claimed, whether or not such alternate,
interchangeable and/or equivalent structures, functions, ranges or
steps are disclosed herein, and without intending to publicly
dedicate any patentable subject matter.
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