U.S. patent application number 15/621614 was filed with the patent office on 2017-12-14 for system and method for replacing and adjusting continuous casting components.
The applicant listed for this patent is Golden Aluminum, Inc.. Invention is credited to Chris Michael Moellers.
Application Number | 20170355014 15/621614 |
Document ID | / |
Family ID | 60572205 |
Filed Date | 2017-12-14 |
United States Patent
Application |
20170355014 |
Kind Code |
A1 |
Moellers; Chris Michael |
December 14, 2017 |
SYSTEM AND METHOD FOR REPLACING AND ADJUSTING CONTINUOUS CASTING
COMPONENTS
Abstract
A method includes: replacing a first casting system component by
a second casting component; sensing a position of the second
casting component relative to at least one of a reference position
and a third casting component; determining an adjustment amount
and/or direction of the second casting system component; and
providing the adjustment amount and/or direction to an operator for
adjustment of the second casting system component and/or commanding
that the second casting system component be adjusted by the
adjustment amount and/or direction.
Inventors: |
Moellers; Chris Michael;
(Firestone, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Golden Aluminum, Inc. |
Fort Lupton |
CO |
US |
|
|
Family ID: |
60572205 |
Appl. No.: |
15/621614 |
Filed: |
June 13, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62349463 |
Jun 13, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22D 11/186 20130101;
B22D 11/185 20130101; B22D 11/18 20130101; B22D 11/003 20130101;
B22D 11/004 20130101; B22D 11/143 20130101 |
International
Class: |
B22D 11/14 20060101
B22D011/14; B22D 11/18 20060101 B22D011/18; B22D 11/00 20060101
B22D011/00 |
Claims
1. In a casting system for casting molten metal or alloy, a method,
comprising: replacing a first casting system component by a second
casting component; sensing, by a sensor, a position of the second
casting component relative to at least one of a reference position
and a third casting component; determining, by a microprocessor
executable control system, an adjustment amount and/or direction of
the second casting system component; and the microprocessor
executable control system at least one of providing the adjustment
amount and/or direction to an operator for adjustment of the second
casting system component and commanding that the second 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 first, second, and third casting system
components are first, second, and third chilling blocks, wherein
the second chilling block is adjusted by one or more adjustment
points on the second chilling block, wherein the first chilling
block is disengaged and removed from a track guide supporting
chilling blocks of the casting system and wherein the second
casting component is positioned in a position formerly occupied by
the first chilling block and engaged with the track guide.
3. The method of claim 2, wherein the at least one of a reference
position and a third casting component is the third casting
component, 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, wherein
the replacing, sensing, determining, and at least one of providing
and commanding steps occur while the casting system is casting a
metal or metal alloy, and wherein the molten metal or metal alloy
is one or more of manganese, a manganese alloy, aluminum, an
aluminum alloy, copper, a copper alloy, iron, and an iron
alloy.
4. The method of claim 2, further comprising selecting the second
casting component from among multiple possible casting components
to replace the first casting component, wherein the replacing step
is performed by a block changer, the block changer being one or
more of a robotic arm, a boom, a push arm or piston, and a pull arm
or piston.
5. The method of claim 4, wherein the multiple possible casting
components are positioned in multiple cartridges and wherein the
first casting component when removed is positioned in a
cartridge.
6. The method of claim 4, wherein the replacing step comprises
disengaging the first casting component from the guide track,
removing the first casting component from a first position on the
guide track, positioning the second casting component at the first
position on the guide track, and engaging the second casting
component with the guide track.
7. The method of claim 4, wherein the replacing step comprises
locating the second casting component adjacent to the first casting
component, maintaining the second casting component adjacent to the
first casting component as the first casting component moves in
response to operation of the casting system, displacing, by contact
with the second casting component, the first casting component from
a first position on the guide track and locating the second casting
component in the first guide track position.
8. A tangible and non-transitory computer readable medium,
comprising microprocessor executable instructions operable to
perform functions comprising: one or more instructions to replace a
first casting system component of a casting system by a second
casting component; one or more instructions to sense, by a sensor,
a position of the second casting component relative to at least one
of a reference position and a third casting component; one or more
instructions to determine an adjustment amount and/or direction of
the second casting system component; and one or more instructions
to at least one of provide the adjustment amount and/or direction
to an operator for adjustment of the second casting system
component and command that the second casting system component be
adjusted by the adjustment amount and/or direction.
9. The medium of claim 8, wherein the casting system is a block
caster, wherein the first, second, and third casting system
components are first, second, and third chilling blocks, wherein
the second chilling block is adjusted by one or more adjustment
points on the second chilling block, wherein the first chilling
block is disengaged and removed from a track guide supporting
chilling blocks of the casting system, and wherein the second
casting component is positioned in a position formerly occupied by
the first chilling block and engaged with the track guide.
10. The medium of claim 9, wherein the at least one of a reference
position and a third casting component is the third casting
component, 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, wherein
the replacing, sensing, determining, and at least one of providing
and commanding functions occur while the casting system is casting
a metal or metal alloy, and wherein the molten metal or metal alloy
is one or more of manganese, a manganese alloy, aluminum, an
aluminum alloy, copper, a copper alloy, iron, and an iron
alloy.
11. The medium of claim 9, further comprising one or more
instructions to select the second casting component from among
multiple possible casting components to replace the first casting
component, wherein the replacing function is performed by a block
changer, the block changer being one or more of a robotic arm, a
boom, a push arm or piston, and a pull arm or piston.
12. The medium of claim 11, wherein the multiple possible casting
components are positioned in multiple cartridges and wherein the
first casting component when removed is positioned in a
cartridge.
13. The medium of claim 11, wherein the replacing function
comprises disengaging the first casting component from the guide
track, removing the first casting component from a first position
on the guide track, positioning the second casting component at the
first position on the guide track, and engaging the second casting
component with the guide track.
14. The medium of claim 11, wherein the replacing function
comprises locating the second casting component adjacent to the
first casting component, maintaining the second casting component
adjacent to the first casting component as the first casting
component moves in response to operation of the casting system,
displacing, by contact with the second casting component, the first
casting component from a first position on the guide track, and
locating the second casting component in the first guide track
position.
15. 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 casting
component changer to replace a first casting component by a second
casting component; a sensor to sense a position of the second
casting component relative to at least one of a reference position
and a third casting component; and a microprocessor executable
control system operable to determine an adjustment amount and/or
direction of the second casting system component and at least one
of provide the adjustment amount and/or direction to an operator
for adjustment of the second casting system component and command
that the second casting system component be adjusted by the
adjustment amount and/or direction.
16. The casting system of claim 15, wherein the casting system is a
block caster, wherein the first, second, and third casting system
components are first, second, and third chilling blocks, wherein
the second chilling block is adjusted by one or more adjustment
points on the second chilling block, wherein the first chilling
block is disengaged and removed from a track guide supporting
chilling blocks of the casting system, and wherein the second
casting component is positioned in a position formerly occupied by
the first chilling block and engaged with the track guide.
17. The casting system of claim 16, wherein the at least one of a
reference position and a third casting component is the third
casting component, 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, wherein the replacing, sensing, determining, and at
least one of providing and commanding operations occur while the
casting system is casting a metal or metal alloy, and wherein the
molten metal or metal alloy is one or more of manganese, a
manganese alloy, aluminum, an aluminum alloy, copper, a copper
alloy, iron, and an iron alloy.
18. The casting system of claim 16, wherein the microprocessor
executable control system is operable to select the second casting
component from among multiple possible casting components to
replace the first casting component and wherein the casting
component changer is one or more of a robotic arm, a boom, a push
arm or piston, and a pull arm or piston.
19. The casting system of claim 18, wherein the multiple possible
casting components are positioned in multiple cartridges and
wherein the first casting component when removed is positioned in a
cartridge.
20. The casting system of claim 18, wherein the replacing operation
comprises disengaging the first casting component from the guide
track, removing the first casting component from a first position
on the guide track, positioning the second casting component at the
first position on the guide track, and engaging the second casting
component with the guide track.
21. The casting system of claim 18, wherein the replacing operation
comprises locating the second casting component adjacent to the
first casting component, maintaining the second casting component
adjacent to the first casting component as the first casting
component moves in response to operation of the casting system,
displacing, by contact with the second casting component, the first
casting component from a first position on the guide track, and
locating the second casting component in the first guide track
position.
22. The casting system of claim 15, 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.
23. The casting system of claim 15, wherein the casting assembly
comprises one or more of a single-belt caster, twin-belt caster,
single-roll caster, twin-roll caster, and rotary caster, 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 replacement casting
assembly component.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefits of U.S.
Provisional Application Ser. No. 62/349,463, filed Jun. 13, 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 (or nearly 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. A
depression on the back side of a belt caster can pulse the entire
belt, much like an Indian smoke signal blanket. Belt casters can
have a depression from grinding the weld joint below flush. A
surface defect can also result from a bad caster stop event.
[0006] Other continuous casting systems include without limitation
single-roll casters, twin-roll casters, and rotary casters.
[0007] Periodically, components, such as blocks and back-up rolls,
need to be repaired or replaced due to the effects of wear or
damage. Component repair or replacement often require the caster to
be shut down, with concomitant loss of cast strip production. The
economic cost of lost cast strip production can be substantial
depending on caster down time.
[0008] There is therefore a need to repair or replace caster
components during caster operation or without interrupting caster
operation.
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, thereby enabling repair
and/or replacement of caster components during caster operation or
without interrupting caster operation.
[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 casting component changer to replace a first casting
component by a second casting component;
[0014] a sensor to sense a position of the second casting component
relative to a reference position and/or third casting component;
and
[0015] a microprocessor executable control system operable to
determine an adjustment amount and/or direction of the second
casting system component and provide the adjustment amount and/or
direction to an operator for adjustment of the second casting
system component and/or command that the second casting system
component be adjusted by the adjustment amount and/or
direction.
[0016] The casting system can be a block caster. In that case, the
first, second, and third casting system components are first,
second, and third chilling blocks. The second chilling block can be
adjusted by one or more adjustment points on the second chilling
block. The first chilling block can be disengaged and removed from
a track guide supporting chilling blocks of the casting system. The
second casting component can be positioned in a position formerly
occupied by the first chilling block and engaged with the track
guide.
[0017] The sensors can be one or more of a laser radar detector, a
mechanical displacement device, an imaging device, an optical 3d
measuring system, and an ultrasound transducer.
[0018] The replacing, sensing, determining, providing, and/or
commanding operations can occur while the casting system is casting
a metal or metal alloy.
[0019] The molten metal or metal alloy is commonly one or more of
manganese, a manganese alloy, aluminum, an aluminum alloy, copper,
a copper alloy, iron, and an iron alloy.
[0020] The microprocessor executable control system can select the
second casting component from among multiple possible casting
components to replace the first casting component.
[0021] The casting component changer can be one or more of a
robotic arm, a boom, a push arm or piston, and a pull arm or
piston.
[0022] The multiple possible casting components can be positioned
in multiple cartridges. The first casting component, when removed,
can be positioned in a cartridge.
[0023] The replacing operation can include disengaging the first
casting component from the guide track, removing the first casting
component from a first position on the guide track, positioning the
second casting component at the first position on the guide track,
and engaging the second casting component with the guide track.
[0024] The replacing operation can include locating the second
casting component adjacent to the first casting component,
maintaining the second casting component adjacent to the first
casting component as the first casting component moves in response
to operation of the casting system, displacing, by contact with the
second casting component, the first casting component from a first
position on the guide track, and locating the second casting
component in the first guide track position.
[0025] The casting system can further include:
[0026] a launder to receive the molten metal or metal alloy from a
furnace; and
[0027] a tundish and/or headbox to receive the molten metal or
metal alloy from the furnace and provide the melt to the
nozzle.
[0028] The casting assembly can include one or more of a
single-belt caster, twin-belt caster, single-roll caster, twin-roll
caster, and rotary caster.
[0029] The casting assembly component can alternatively be one or
more of a roller, belt, back-up roll, and block belt.
[0030] The microprocessor executable 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.
[0031] The present disclosure can provide a number of advantages
depending on the particular aspect, embodiment, and/or
configuration. The casting system can identify a casting system
component requiring replacement and enable automatic or
semi-automatic component replacement and adjustment of the
replacement casting system component, during casting system
operation, to inhibit, remove, or reduce the formation of surface
defects in a next casting cycle (e.g., next revolution of a roll,
block or belt caster). This can eliminate the need not only for
manual block adjustment but also for shutting down the casting
system to replace a casting system component and reset an
improperly adjusted replacement casting system component. This has
the further benefit of making less expensive continuously cast
strip applicable to a broader variety of applications and
markets.
[0032] These and other advantages will be apparent from the
disclosure.
[0033] 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.o).
[0034] 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.
[0035] "Aluminum alloys" are alloys in which aluminum (Al) is the
predominant metal. The typical alloying elements are copper,
magnesium, manganese, silicon, and zinc.
[0036] 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".
[0037] 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.
[0038] 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.
[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] All percentages and ratios are calculated by total
composition weight, unless indicated otherwise.
[0044] 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.
[0045] All percentages and ratios are calculated by total
composition weight, unless indicated otherwise.
[0046] 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
[0047] 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.
[0048] FIG. 1 depicts a prior art block casting system;
[0049] FIG. 2 depicts a prior art twin-belt casting system;
[0050] FIG. 3 depicts a partial top view of a block casting system
according to an embodiment of this disclosure;
[0051] FIG. 4 depicts a partial side view of a block casting system
according to an embodiment of this disclosure;
[0052] FIG. 5A is a top view of a chilling block according to an
embodiment;
[0053] FIG. 5B is a side view of a chilling block according to an
embodiment;
[0054] FIG. 6 is a partial side view of a block casting system
according to an embodiment of this disclosure;
[0055] FIG. 7 is a partial top view of a block casting system
according to an embodiment of this disclosure;
[0056] FIG. 8 is a side view of a block carrying system according
to an embodiment of this disclosure;
[0057] FIG. 9 is a side view of a block according to an embodiment
of this disclosure;
[0058] FIG. 10 is a flow chart of control logic according to an
embodiment; and
[0059] FIG. 11 is a side view of a modified block caster according
to an embodiment.
DETAILED DESCRIPTION
[0060] FIGS. 3, 4, and 6 depict an embodiment of a block casting
system 300 according to this disclosure. The block casting system
has upper and lower sets 304 of chilling blocks 316, each engaged
with a corresponding endless or continuous track guide 608, to cool
and solidify the molten metal into a cast strip 130, plural sensors
308 located above and below, respectively, each set of upper and
low chilling block sets 304 to detect chilling block surface
irregularities (e.g., steps, offsets, and other interruptions in
the surface planes of adjacent chilling blocks which typically
occur at inter-block joints 320 as shown in FIG. 4 (the solid line
refers to the joint 320 between adjacent chilling blocks 316 in the
upper set 304a of chilling blocks and dashed lines refer to the
joints 320 between adjacent chilling blocks in the lower set 304b
of chilling blocks)) 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 increase adjacent
chilling block surface planarity and thereby substantially minimize
or inhibit formation of surface defects in the cast strip.
[0061] 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 replacing and/or 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.
[0062] While FIGS. 3 and 4 depict the control system with respect
to the upper set of chilling blocks, it is to be understood that a
similar system is used to monitor and adjust the lower set of
chilling blocks.
[0063] Referring to FIGS. 3-4, 5A and 5B, and 6 each chilling block
316 in the upper and lower sets 304 of chilling blocks, which are
positioned on one of the opposing sides of the cast strip 130,
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.
[0064] 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-1 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.
[0065] 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 to
be 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 304 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.
[0066] The sensors 308 can be any device able to detect surface
irregularities in the cast strip-contacting surfaces of the upper
and lower chilling block sets 304. Examples include a laser radar
detector (which uses a laser beam 350 to determine the distance
from the sensor to the block surface), mechanical displacement
device (which measures the vertical variations in travel or
movement of a wheel or other contact device with the block
surface), imaging device (which uses image processing to identify
surface irregularities and other variations in block surface
topology, such as image processing based on the block 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 block 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
chilling block surface). Laser radar, for example, can operate on
the time of flight principle by sending a laser pulse in a narrow
beam towards the chilling block surface to be measured and
measuring the time taken by the pulse to reflect off the target
chilling block surface and return 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 of
electromagnetic energy by the target chilling block surface and
then solves various simultaneous equations to yield a final
distance measure from the sensor to the target chilling block
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 target chilling
block surface is translated into a frequency offset) and
interferometry (which measures changes in distance between the
sensor and the target chilling block 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.
[0067] 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 in the upper or lower set of chilling
blocks (e.g., 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).
[0068] 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 sensor can be 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 respective
sensor 308 can lie in plane 360, the centers of the next row of
adjustment points 328 and respective sensor 308 can lie in plane
364, the centers of the next row of adjustment points 328 and
respective sensor 308 can lie in plane 368, the centers of the next
row of adjustment points 328 and respective sensor 308 can lie in
plane 372, the centers of the next row of adjustment points 328 and
respective sensor 308 can lie in plane 376, and the centers of the
next row of adjustment points 328 and respective sensor 308 can lie
in plane 378. The centers of the upper and lower sets of sensors
308 (the upper set of sensors 308 corresponding to the upper set of
chilling blocks and the lower set of sensors 308 corresponding to
the lower set of chilling blocks) can lie in a common plane
382.
[0069] Each of the upper and lower sets of chilling blocks has
separate adjustment and measurement zones 392 and 396 controlled by
separate or a common adjustment control system 312. Referring to
FIG. 4, the distance 388 between the adjustment 392 and measurement
zones 396 for each of the upper and lower sets of chilling blocks
is selected such that the chilling block currently in the upper or
lower adjustment zone 392 corresponds to a set of distance
measurements previously taken in the corresponding upper or lower
measurement zone 396 by the respective sensor 308. In some
applications, each adjustment zone 392 is located before the cooler
126. In other applications, each adjustment zone 392 is located
after the cooler 126. In yet other applications, each adjustment
zone 396 is located before and/or after the cooler 126 (which
location can be differently selected for the upper versus the lower
chilling block sets). The measurement zone 396 is commonly located
before the cooler 126 but can alternatively or additionally be
located after the cooler 126. FIG. 6 depicts a casting system
configuration in which the measurement zone 308 is located before
the cooler 126 and the corresponding adjustment zone 392 is located
after the cooler 126. 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. If the adjustment zone were
located entirely after the cooler, the cooler would be modified to
accept excessively non-flush conditions. If part of the
adjustments, or the rough adjustments, were performed before the
cooler and the final finer adjustments made after the cooler,
cooler performance would not be substantially impacted adversely
and the cooler would not need to be redesigned.
[0070] Prior to discussing the chilling block replacement operation
of the block casting system 300, 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 inter-block joint surface irregularities in
adjacent chilling blocks commonly alternate between the upper and
lower cast strip surfaces as the cast strip moves through the
measurement and adjustment zones 396. As can be further seen in
FIG. 1, the upper and lower chilling blocks 316 and inter-block
joints 320 move in a common direction when in contact with the cast
strip.
[0071] Each of the upper and lower sets of chilling blocks has a
corresponding block changer 604 (FIG. 6) to slide, rotate, lift, or
translate an old chilling block out of position on the track guide
608 and slide, rotate, lift, or translate, as appropriate, a new
chilling block into old block's position on the track guide. The
block changer 604 can be any device suitable for these operations,
such as a robotic arm, a boom, and a push or pull (e.g.,
telescopic) arm or piston. Mechanical displacement mechanisms for a
push or pull arm of piston include, without limitation, a ratchet
mechanism (e.g., pawl and ratchet), a gear, cogwheel or sprocket
mechanism (e.g., two or more meshing gears, such as spur gear(s),
helical gear(s), double helical gear(s), bevel gear(s), spiral
bevel gear(s), hypoid gear(s), crown gear(s), worm gear(s),
non-circular gear(s), rack and pinion gear(s), epicyclic gear(s),
sun and planet gear(s), harmonic gear(s), cage gear(s), and
magnetic gear(s)). Other displacement mechanisms include, without
limitation, hydraulic, electromechanical, and electromagnetic
mechanisms.
[0072] FIGS. 7-9 depict an embodiment of a block changing system
700. The block changing system 700 includes a block changer 604,
set of new blocks 704, and set of old (or previously replaced)
blocks 708. The sets of new and old blocks are positioned on either
side of the set of upper or lower chilling blocks 304, which are in
operation producing cast strip 130. Alternatively, the sets of new
and old blocks can be positioned on a common side of the set of
upper or lower chilling blocks 304. When a selected one of the set
of upper or lower chilling blocks 304 is to be replaced, the block
is disengaged from the track guide 608, a new block 316 pushed by
the block changer 604 from the set of new blocks 704 against the
selected one of the set of upper or lower chilling blocks, thereby
displacing it from its disengaged operating position on the track
guide and moving it to the set of old blocks. When the new block is
in the disengaged operating position on the track guide, it is
engaged with the track guide to place or lock it in operating
position for casting the cast strip 130. The selected one of the
upper or lower chilling blocks 708 can be guided out of the
disengaged operating position by an integral rail or track or other
guidance system. Although the selected one of the set of upper or
lower chilling blocks 708 is shown as being displaced out of
position by contact with the new block 316, the selected one of the
upper or lower chilling blocks 708 can be moved out of the
operating position and the new block moved into the same operating
position with no inter-block contact.
[0073] To facilitate block exchange, a cartridge system can be
employed. The replaced block can be slid out of disengaged
operating position into an empty receiving cartridge (not shown).
The now occupied receiving cartridge is then moved away from the
upper or lower set of chilling blocks and a new empty receiving
cartridge moved into alignment with the next selected one of the
set of upper or lower chilling blocks 708 to be replaced. Likewise,
the new block can be moved out of a receiving cartridge (not shown)
and into the disengaged operating position followed by movement of
the now empty receiving cartridge away from the upper or lower set
of chilling blocks. Receiving cartridges assist in positioning and
aligning the new blocks with the selected one of the set of upper
or lower chilling blocks 708 to be replaced and removing the
replaced block. The next cartridge containing a new block is moved
into alignment with the next selected one of the set of upper or
lower chilling blocks 708 to be replaced and the process repeated.
In one configuration, the cartridges are on a common carrier
positioned on a common side of the set of upper or lower chilling
blocks. With both old and new blocks on the common side, the block
changer moves new blocks and empties cartridges and moves replaced
blocks into the now emptied cartridges.
[0074] As will be appreciated, the two block cartridges (i.e.,
empty cartridge to receive the replaced block and cartridge
containing the new block) each need to be aligned simultaneously
with the chilling block to be replaced and move synchronously with
(e.g., move at the same speed as) the chilling block to be replaced
to enable continuous and uninterrupted caster operation. This can
be effected by connecting or engaging the cartridges with the track
guide. An example of this type of system is shown in FIG. 8. Old or
new blocks 316 are positioned on a carrier structure 800 having one
or more rotatable supports 804 to enable the carrier structure 800
to move back and forth in response to movement of a translation
mechanism 808. The translation can be hydraulic, mechanical,
electrical, electromagnetic, or electromechanical. In the depicted
translation mechanism 808, a hydraulic pump 812 moves a telescopic
hydraulic cylinder 816 engaged with a connector 820 on the carrier
structure forward in response to movement with the selected one of
the set of upper or lower chilling blocks and backward after block
replacement to position to replace a next block. As will be
appreciated, other carrier structures can be employed depending on
the application.
[0075] In another configuration, one or more robotic arms is/are
employed. A first robotic arm engages the selected one of the set
of upper and lower chilling blocks to be replaced and follows the
selected block as the caster is moving. A second robotic arm pulls
a new block from a rack, the selected block is disengaged from the
track guide, the first robotic arm moves the selected block from
the disengaged operating position to a rack, while the second
robotic arm places the new block into the disengaged operating
position. Then, the new block is engaged with the track guide.
[0076] The engagement and disengagement of the selected block with
and from the track guide can be by any suitable mechanism.
Referring to FIG. 9, one or more adjustment points 328 of a
chilling block include an inward or outward facing pin 900 that
releasably engages a hole or slot in a connector (not shown) on the
track guide. The pin engages the connector when the block is in the
engaged operating position and does not engage the connector when
the block is in the disengaged operating position. The track guide
can include one or more channels (not shown) along which the
downwardly protruding ends 904 of the adjustment points 328 are
guided in response to movement of the chilling block. Other
non-limiting examples of engagement/disengagement mechanisms
include a pin on the track guide connector that engages a hole or
slot in the protruding end 904 of the adjustment point 328,
moveable members on the track guide that engage and disengage a
hole or slot in the block 316, moveable members on the block 316
that engage and disengage a hole or slot in the track guide, a pawl
and ratchet mechanism, spring-loaded mechanisms, and the like.
[0077] FIG. 11 shows a circular block caster 1100 that is a
combination of a roll caster and block caster. As can be seen from
FIG. 11, each of the upper and lower sets of chilling blocks 1104a
and b includes a plurality of chilling blocks 1108 engaging a
central mandrel 1112. The upper and lower faces of each chilling
block are arcuately shaped. Each of the upper and lower sets of
chilling blocks are cooled by a cooler 1116. Each of the chilling
blocks 1108 can be independently and selectively replaced and
adjusted in any manner, including by the techniques disclosed
above.
[0078] The operation of the adjustment control system will now be
discussed with reference to FIG. 10.
[0079] In step 1000, the adjustment control system 312 selects a
chilling block in one of the sets of upper and lower chilling
blocks to be replaced. The selection can be based on user input
and/or parameters sensed by one or more sensors. For example,
consistently sensing a surface defect in a portion of a cast strip
contacted by a given block indicates that the block is damaged or
worn and requires replacement. The sensing can be based on a vision
or dimension defect on the cast strip. When such a defect is
sensed, the responsible chilling block (in the set of upper and
lower set of chilling blocks casting the defect-containing upper or
lower cast strip surface) is identified, such as by determining a
rate of advance of the cast strip and/or rate of rotation of the
chilling blocks and, based on the distance traversed by the cast
strip during the time interval since the defect was first or last
contacted with a chilling block and ending when the defect was
sensed, determining the chilling block located at that distance
along the face of the block caster. The defect can be sensed by any
of the sensors identified above. The sensors can be the same as or
in addition to the sensors providing feedback to control chilling
block adjustment.
[0080] In step 1004, the adjustment control system 312 determines
the selected chilling block's dimensions. This can be done by any
technique, including user input or a look up table mapping the
identity of the selected block against one or more dimensions
(e.g., length, width, and/or thickness) of the block. A robotic arm
can measure one or more dimensions of the selected block. As will
be appreciated, a non-contact device can remain stationary and
timely measure the dimensions.
[0081] In step 1008, the adjustment control system 312 selects a
new or replacement chilling block having one or more similar
dimension(s). This can be done by any technique, including user
input or a look up table mapping the positions of the replacement
blocks against one or more dimensions (e.g., length, width, and/or
height) of the block. A robotic arm can measure one or more
selected dimensions of each of the replacement blocks and select
that replacement block having the closest selected
dimension(s).
[0082] In step 1012, the adjustment control system 312 aligns the
selected replacement block with the selected block to be replaced
and replaces the selected block. A look up table can be updated to
reflect one or more dimension(s) of the replacement block for the
block dimensions of the corresponding block operating position in
the set of upper or lower chilling blocks. Optionally, the
adjustment control system 312 can, based on the difference between
the thicknesses of the replaced block and the replacement block,
effect rough adjustments to form a substantially planar surface
with adjacent chilling blocks. The system should be able to handle
the entire range of block dimensions. It is possible, however, to
design a block casting system in which all of the blocks are
relatively close in dimension (particularly when the expansion and
contraction of thermal heating and cooling events occurs).
[0083] In step 1016, the adjustment control system 312 selects a
sensor corresponding to a selected adjustment point in the
measurement zone. The control system can identify a set of
adjustment points for the replacement chilling block and/or
inter-block joint entering the adjustment zone in many ways. In one
technique, a position of a selected chilling block and/or
inter-block joint 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 track guides in the
case of a belt caster). Based on this monitored location, the
locations of the other chilling block and/or inter-block joints are
readily determined (as the chilling blocks have known widths and/or
are in a predictable constant sequence as the supporting track
guide moves through each revolution). 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.
[0084] In step 1020, the control system 312 receives measurements
from the selected sensor and determines a distance to the
replacement block surface. The control system 312, as will be
appreciated, can query the selected sensor for a set of readings or
receive multiple sets of sensor readings from all sensors and
select the appropriate set of readings, based on the identities of
the source sensor. The selected set of sensor readings can enable
the control system 312 to determine the distance at the point of
measurement.
[0085] In step 1024, the control system 312 compares the measured
distance to a predetermined or reference distance and/or a distance
measured to a portion of the block surface of an adjacent block
and, in decision diamond 1028, determines whether or not to adjust
the selected adjustment point(s). When an absolute value of a
difference in the measured distance from the predetermined or
reference distance is at least a predetermined threshold, the
control system 312 proceeds to step 1032. Alternatively, the
control system 312 can determine a difference of the measured
distance from a distance measured by a prior set of sensor readings
from the selected sensor for an adjustment point (or a portion of
the block surface of an adjacent block) in the same plane and/or a
distance measured by one or more adjacent sensor(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
1032.
[0086] In step 1032, the control system 312 determines an
adjustment amount and direction (e.g., up or down and either
commands the selected adjustment point(s) to be adjusted (by a
control signal addressed to the unique identifier of the adjustment
point) to the determined adjustment amount and direction or
recommends to a human user the adjustment amount and direction for
manual adjustment of the adjustment point 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 step height over the inter-block joint 320
at or less than a predetermined magnitude. The target adjustment
amount may be equivalent to the difference between the measured
distance on either side of the inter-block joint 320 or a fraction
or percentage thereof. The adjustment points 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 distance on either side of the inter-block joint
can be measured and each adjustment point on either side of the
joint adjusted to produce a substantially identical distance at its
respective location.
[0087] After step 1032 or when no adjustment is required, the
control system, in decision diamond 1036 determines whether there
is an adjustment point or set of adjustment points 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.
[0088] When a further adjustment point(s) for the inter-block joint
remains to be considered for adjustment, the control system returns
to step 1016.
[0089] When no further adjustment points for the inter-block joint
remain to be considered for adjustment, the control system returns
to step 1000.
[0090] The disclosure can apply to detection of and/or continuous
casting component replacement and adjustment and inhibit surface
defects other than impressions left by block joints. For example,
the disclosure can apply to any of the surface defects discussed
above.
[0091] The disclosure can apply to automatic replacement and
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 replaced and adjusted can be the back-up rolls 212
so as to maintain a substantially planar surface of the belt
contacting the cast strip 130. In a belt caster, there can be
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 back-up roll can
be replaced by a robotic arm or other suitable automated technique
followed by adjustment of the replacement back-up roll, which
commonly has dimensional adjustments at the bearings. The same can
be true of a roll caster, with eccentricities, flat spots, and
coating thickness variations. The roll can be replaced by a robotic
arm or other suitable automated technique followed by adjustment of
the replacement roll, which commonly has a point of adjustment or
adjustment point at the bearing points. There are commonly 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.
[0092] 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.
[0093] A 1000 series-based aluminum alloy typically has the
following composition:
[0094] (i) from about 0.05 to about 0.20% by weight magnesium;
[0095] (ii) from about 0.01 to about 0.20% by weight manganese;
[0096] (iii) from about 0.01 to about 0.25% by weight copper;
[0097] (iv) from about 0.001 to about 0.08% by weight iron;
[0098] (v) from about 0.001 to about 0.02% by weight silicon;
[0099] (vi) from about 0.001 to about 0.095% by weight
chromium;
[0100] (vii) from about 0.01 to about 0.45% by weight zinc;
[0101] (viii) from about 0.001 to about 0.045% by weight
nickel;
[0102] (ix) from about 0.01 to about 0.175% by weight titanium;
and
[0103] (x) no more than about 0.05 wt. % other impurities.
[0104] A 2000 series-based aluminum alloy typically has the
following composition:
[0105] (i) from about 0.02 to about 1.8% by weight magnesium;
[0106] (ii) from about 0.1 to about 1.2% by weight manganese;
[0107] (iii) from about 1.8 to about 6.8% by weight copper;
[0108] (iv) from about 0.07 to about 1.0% by weight iron;
[0109] (v) from about 0.05 to about 0.5% by weight silicon;
[0110] (vi) from about 0.05 to about 0.8% by weight chromium;
[0111] (vii) from about 0.05 to about 1.4% by weight zinc;
[0112] (viii) from about 0.01 to about 0.2% by weight nickel;
[0113] (ix) from about 0.01 to about 0.175% by weight titanium;
and
[0114] (x) no more than about 0.05 wt. % other impurities.
[0115] A 3000 series-based aluminum alloy typically has the
following composition:
[0116] (i) from about 0.01 to about 1.3% by weight magnesium;
[0117] (ii) from about 0.01 to about 1.3% by weight manganese;
[0118] (iii) from about 0.01 to about 0.3% by weight copper;
[0119] (iv) from about 0.1 to about 0.7% by weight iron;
[0120] (v) from about 0.10 to about 1.7% by weight silicon;
[0121] (vi) from about 0.01 to about 0.35% by weight chromium;
[0122] (vii) from about 0.001 to about 0.09% by weight zinc;
[0123] (viii) from about 0.001 to about 0.09% by weight nickel;
[0124] (ix) from about 0.001 to about 0.09% by weight titanium;
and
[0125] (x) no more than about 0.15 wt. % other impurities.
[0126] A 4000 series-based aluminum alloy typically has the
following composition:
[0127] (i) from about 0.05 to about 2.0% by weight magnesium;
[0128] (ii) from about 0.05 to about 1.5% by weight manganese;
[0129] (iii) from about 0.05 to about 5.0% by weight copper;
[0130] (iv) from about 0.09 to about 1.0% by weight iron;
[0131] (v) from about 0.6 to about 13.5% by weight silicon;
[0132] (vi) from about 0.05 to about 0.25% by weight chromium;
[0133] (vii) from about 0.05 to about 1.3% by weight zinc;
[0134] (viii) from about 0 to about 2.2% by weight nickel;
[0135] (ix) from about 0.5 to about 0.3% by weight titanium;
and
[0136] (x) no more than about 0.05 wt. % other impurities.
[0137] A 5000 series-based aluminum alloy useful for producing tab
or end stock has the following composition:
[0138] (i) from about 2.0 to about 5.0% by weight magnesium;
[0139] (ii) from about 0.10 to about 1.25% by weight manganese;
[0140] (iii) from about 0.001 to about 0.45% by weight copper;
[0141] (iv) from about 0.1 to about 0.85% by weight iron;
[0142] (v) from about 0.1 to about 1.3% by weight silicon;
[0143] (vi) from about 0.01 to about 0.3% by weight chromium;
[0144] (vii) from about 0.75 to about 2.7% by weight zinc;
[0145] (viii) from about 0.001 to about 0.045% by weight
nickel;
[0146] (ix) from about 0.01 to about 0.175% by weight titanium;
and
[0147] (x) no more than about 0.15 wt. % other impurities.
[0148] A 6000 series-based aluminum alloy typically has the
following composition:
[0149] (i) from about 0.2 to about 3.0% by weight magnesium;
[0150] (ii) from about 0.05 to about 1.0% by weight manganese;
[0151] (iii) from about 0.05 to about 0.9% by weight copper;
[0152] (iv) from about 0.1 to about 0.8% by weight iron;
[0153] (v) from about 0.3 to about 1.5% by weight silicon;
[0154] (vi) from about 0.03 to about 0.35% by weight chromium;
[0155] (vii) from about 0.05 to about 1.0% by weight zinc;
[0156] (viii) from about 0 to about 0.2% by weight nickel;
[0157] (ix) from about 0 to about 0.2% by weight titanium; and
[0158] (x) no more than about 0.05 wt. % other impurities.
[0159] A 7000 series-based aluminum alloy typically has the
following composition:
[0160] (i) from about 0.1 to about 3.3% by weight magnesium;
[0161] (ii) from about 0.04 to about 0.8% by weight manganese;
[0162] (iii) from about 0.1 to about 2.8% by weight copper;
[0163] (iv) from about 0 to about 0.5% by weight iron;
[0164] (v) from about 0.05 to about 0.4% by weight silicon;
[0165] (vi) from about 0.04 to about 0.28% by weight chromium;
[0166] (vii) from about 0.8 to about 12% by weight zinc;
[0167] (viii) from about 0 to about 0.03% by weight nickel;
[0168] (ix) from about 0.03 to about 0.2% by weight titanium;
and
[0169] (x) no more than about 0.05 wt. % other impurities.
[0170] 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 be 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.
[0171] 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.
[0172] 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.
[0173] 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).
[0174] 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.
[0175] 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.
[0176] 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.
[0177] 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 casting
component wear on casting performance and cast strip surface
properties/defects and adjusting adjustment points over time and
modify when the component is replaced and 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.
[0178] 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.
[0179] 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.
[0180] 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.
[0181] 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.
[0182] 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, sub combinations, 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.
[0183] 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.
[0184] 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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