Systems and methods for monitoring castings

Abstract

A control system for a casting process includes a sensor positioned to monitor a property of a cast product during the casting process and provide a corresponding sensing signal. The control system also includes a processing circuit configured to generate a real-time model of the cast product based on the corresponding sensing signal and determine a control variable using the real-time model of the cast product. The control variable relates to a real-time modification of the cast product.

1 . A control system for a casting process, comprising:
 a sensor positioned to monitor a property of a cast product during the casting process and provide a corresponding sensing signal; and   a processing circuit configured to:
 generate a real-time model of the cast product based on the corresponding sensing signal; and 
 determine a control variable using the real-time model of the cast product, wherein the control variable relates to a real-time modification of the cast product. 
   
     
     
         2 - 22 . (canceled) 
     
     
         23 . The system of  claim 1 , wherein the property of the cast product includes at least one of a temperature, a flow, a stress, a strain, a viscosity, a porosity, a phase boundary, a conductivity, a current, and a magnetic field of the cast product. 
     
     
         24 . The system of  claim 1 , wherein the control variable relates to at least one of an applied surface heating, an applied surface cooling, an applied volumetric heating, an applied surface force, an applied volumetric force, an applied surface displacement, an applied current, an applied magnetic field, and an applied voltage. 
     
     
         25 . The system of  claim 1 , wherein the processing circuit is configured to determine the control variable by optimizing a casting function relating to a condition of the cast product. 
     
     
         26 . The system of  claim 25 , wherein the condition of the cast product includes at least one of a phase, a phase distribution, a porosity, a strength, a stress characteristic, a strain characteristic, a fatigue characteristic, a creep characteristic, a vibrational mode, a vibrational frequency, a ductility, a stress-strain characteristic, and a uniformity of the cast product. 
     
     
         27 . The system of  claim 25 , wherein the condition of the cast product includes at least one of an expense, a work input, a heating input, and a cooling input required during the casting process. 
     
     
         28 . The system of  claim 25 , wherein the processing circuit is configured to optimize the casting function while satisfying a constraint function. 
     
     
         29 . The system of  claim 28 , wherein the constraint function includes a threshold value for the control variable. 
     
     
         30 . The system of  claim 28 , wherein the constraint function includes at least one of a time, a material usage, an expense, a work input, a heating input, and a cooling input associated with the casting process. 
     
     
         31 . The system of  claim 25 , wherein the processing circuit is configured to optimize the casting function by evaluating the effect on the casting function of a first control strategy and a second control strategy in real-time. 
     
     
         32 . The system of  claim 31 , wherein the processing circuit is configured to evaluate the first control strategy and the second control strategy in parallel. 
     
     
         33 . The system of  claim 31 , wherein the processing circuit is configured to determine the first control strategy based on differentiation of the casting function with respect to a first control variable, and wherein the processing circuit is configured to determine the second control strategy based on differentiation of the casting function with respect to a second control variable. 
     
     
         34 . The system of  claim 31 , wherein the processing circuit is configured to determine the first control strategy using a filter relating a first control variable to the corresponding sensing signal, and wherein the processing circuit is configured to determine the second control strategy using the filter relating a second control variable to the corresponding sensing signal. 
     
     
         35 - 50 . (canceled) 
     
     
         51 . A casting apparatus, comprising:
 a mold configured to receive molten material as part of a casting process, wherein the mold includes a sidewall that at least partially shapes a cast product;   a sensor positioned to monitor a property of the cast product during the casting process and provide a corresponding sensing signal;   a processing circuit configured to:
 generate a real-time model of the cast product based on the corresponding sensing signal; and 
 determine a control variable using the real-time model of the cast product; and 
   a regulation system configured to modify the cast product during the casting process as a function of the control variable.   
     
     
         52 - 67 . (canceled) 
     
     
         68 . The apparatus of  claim 51 , wherein the regulation system includes an actuator coupled to the processing circuit and configured to apply a force to the cast product during the casting process, wherein the force varies based on the control variable. 
     
     
         69 . The apparatus of  claim 68 , wherein the force includes at least one of a surface force and a volumetric force. 
     
     
         70 . The apparatus of  claim 68 , wherein at least one of a magnitude, a location, and a direction of the force varies based on the control variable. 
     
     
         71 . The apparatus of  claim 51 , wherein the regulation system includes a thermal regulation system coupled to the processing circuit and configured to vary the temperature of the cast product during the casting process. 
     
     
         72 . The apparatus of  claim 71 , wherein the thermal regulation system includes a heater configured to provide at least one of surface heating and volumetric heating to the cast product. 
     
     
         73 . The apparatus of  claim 71 , wherein the thermal regulation system includes an electrical device configured to resistively heat at least one of a surface and a volume of the cast product. 
     
     
         74 . The apparatus of  claim 71 , wherein the thermal regulation system is configured to reduce the temperature of the cast product. 
     
     
         75 . The apparatus of  claim 74 , wherein the thermal regulation system includes a spray nozzle configured to apply a coolant fluid to an outer surface of the cast product. 
     
     
         76 . The apparatus of  claim 74 , wherein the thermal regulation system includes a conduit configured to transport a coolant fluid in thermal contact an outer surface of the cast product. 
     
     
         77 . The apparatus of  claim 51 , wherein the regulation system includes an electrical device coupled to the processing circuit and positioned to engage the cast product with an electrical signal. 
     
     
         78 . The apparatus of  claim 77 , wherein the electrical device is configured to apply at least one of a current, an electric field, and a voltage to the cast product. 
     
     
         79 . The apparatus of  claim 51 , wherein the regulation system includes a magnetic field generator coupled to the processing circuit and positioned to apply a magnetic field to the cast product, wherein the magnetic field varies based on the control variable. 
     
     
         80 - 97 . (canceled) 
     
     
         98 . A casting apparatus, comprising:
 a mold configured to receive molten material as part of a casting process, wherein the mold includes a sidewall that at least partially shapes a cast product;   a first probe configured to engage the cast product with a test signal and provide a sensing signal relating to a property of the cast product;   a processing circuit configured to:
 determine a volumetric temperature profile of the cast product during the casting process based on the sensing signal; and 
 determine a control variable using the volumetric temperature profile; and 
   a regulation system configured to modify the cast product during the casting process as a function of the control variable.   
     
     
         99 . The apparatus of  claim 98 , wherein the first probe includes an ultrasound transducer and the test signal includes a plurality of ultrasound waves, wherein interaction of the plurality of ultrasound waves with the cast product produces a plurality of response signals, and wherein the sensing signal is related to the plurality of response signals. 
     
     
         100 . The apparatus of  claim 99 , wherein the first probe is configured to engage the cast product with the test signal by at least one of transmitting the plurality of ultrasound waves and receiving the plurality of response signals. 
     
     
         101 - 109 . (canceled) 
     
     
         110 . The apparatus of  claim 98 , wherein the first probe includes at least one of an electrical signal generator and an electrical signal receiver and the test signal includes an electrical signal, wherein the sensing signal is related to an amount of current that passes through the cast product. 
     
     
         111 . The apparatus of  claim 110 , wherein the processing circuit is configured to determine the volumetric temperature profile of the cast product based on the thermal variation of electrical conductivity. 
     
     
         112 . The apparatus of  claim 98 , wherein the first probe includes at least one of a magnetic field generator and a magnetic field sensor and the test signal includes a magnetic field. 
     
     
         113 . The apparatus of  claim 112 , wherein the processing circuit is configured to determine the volumetric temperature profile of the cast product based on the thermal variation of permeability. 
     
     
         114 - 116 . (canceled) 
     
     
         117 . The apparatus of  claim 98 , wherein the processing circuit is configured to generate a real-time model of the cast product based on the sensing signal, and wherein the processing circuit is configured to determine the control variable using a simulation-based control algorithm. 
     
     
         118 . The apparatus of  claim 98 , wherein the processing circuit is configured to determine the control variable using a parametric control algorithm. 
     
     
         119 - 239 . (canceled)