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.

What is claimed is: 
     
         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.