Apparatus for the automatic startup of a continuous casting line

Abstract

An apparatus for the automatic startup of a continuous casting line, including a vessel which is connected to a tip by means of a gate, the tip feeding a casting housing. The apparatus includes a laser device which measures the level of the metal within the vessel, a level control device, which adjusts the introduction of liquid metal into the vessel, a gate actuator to control the gate for providing a barrier between the vessel and the tip, a transducer for the temperature of the metal inside the vessel, and a PLC which receives data from the temperature transducer and from the laser device to control the level control device and the gate actuator, so as to adjust the vessel metal level to ensure a correct and continuous flow of metal toward the casting cylinders, to avoid poor diffusion of the metal inside the tip.

1 - 8 . (canceled) 
     
     
         9 . An apparatus in a continuous casting line, comprising:
 a vessel;   a tip connected to said vessel and defining an outlet, said tip feeding a casting housing, said casting housing comprising casting rollers;   a spraying system configured to water-cool said casting rollers;   a water feeding system feeding water to said spraying system, said water feeding system comprising at least one water intake having a temperature control thermocouple, a flow control valve, and a pressure control valve, at least one water outlet having a pressure control valve, and a temperature control thermocouple;   a gate at said outlet, providing a movable or adjustable barrier between the vessel and the tip;   a laser device which measures the level of the metal within said vessel;   ducts connecting said vessel to molten metal collection trays;   a level control device, which adjusts the introduction of liquid metal into said vessel;   a gate actuator operatively connected to said gate to control said gate, said gate actuator being operated by a gear train connected to a brush less motor with feedback position control;   a transducer for sensing temperature of metal inside said vessel; and   an electronic management unit operatively connected to said transducer and said laser device and configured to carry out an automatic startup process including (a) holding said gate in a closed position during a startup phase, (b) once a predetermined start temperature of liquid metal in said vessel has been attained, as measured by said transducer, sending a command to said level control device to reach a set closure position, and (c) once a predetermined set point in the level of liquid metal in said vessel has been attained, as determined by readings of said laser device, operating said gate actuator to open said gate gradually and progressively in accordance with a stored positioning profile, said electronic management unit being further configured to carry out a continuous state process including controlling said level control device and said gate actuator to adjust the level of said metal in said vessel in order to ensure a correct and continuous flow of metal toward said casting housing, said electronic management unit being further configured to adjust the speed of said rollers and the cooling water dispensed by said spraying system.   
     
     
         10 . The apparatus according to  claim 9 , wherein said casting housing comprises two casting rollers, said water feeding system comprising:
 an upper roller water intake having a temperature control thermocouple, a flow control valve, and a pressure control valve;   a lower roller water intake having a temperature control thermocouple, a flow control valve, and a pressure control valve;   an upper roller water outlet having a pressure control valve and a temperature control thermocouple; and   a lower roller water outlet having a pressure control valve and a temperature control thermocouple.   
     
     
         11 . The apparatus according to  claim 9 , wherein said electronic management unit comprises a programmable logic controller (PLC). 
     
     
         12 . The apparatus according to  claim 9 , wherein said transducer comprises a thermocouple. 
     
     
         13 . The apparatus according to  claim 9 , wherein said gate comprises a refractory barrier. 
     
     
         14 . A method for an automatic startup of a continuous casting line, wherein said continuous casting line comprises:
 a vessel;   a tip connected to said vessel and defining an outlet, said tip feeding a casting housing, said casting housing comprising casting rollers;   a spraying system configured to water-cool said casting rollers;   a water feeding system feeding water to said spraying system, said water feeding system comprising (i) at least one water intake having a temperature control thermocouple, a flow control valve, and a pressure control valve, and (ii) at least one water outlet having a pressure control valve, and a temperature control thermocouple;   a gate at said outlet, providing a movable or adjustable barrier between the vessel and the tip;   a laser device which measures the level of the metal within said vessel;   ducts connecting said vessel to molten metal collection trays;   a level control device, which adjusts the introduction of liquid metal into said vessel;   a gate actuator operatively connected to said gate to control said gate, said gate actuator being operated by a gear train connected to a brushless motor with feedback position control;   a transducer for sensing temperature of metal inside said vessel; and   an electronic management unit operatively connected to said transducer and said laser device and configured to carry out an automatic startup process;   said method comprising:   (a) holding said gate in a closed position during a startup phase,   (b) once a predetermined start temperature of liquid metal in said vessel has been attained, as measured by said transducer, sending a command to said level control device to reach a set closure position, and   (c) once a predetermined set point in the level of liquid metal in said vessel has been attained, as determined by readings of said laser device, operating said gate actuator to open said gate gradually and progressively in accordance with a stored positioning profile, and further configured to carry out a continuous state process including controlling said level control device and said gate actuator to adjust the level of said metal in said vessel in order to ensure a correct and continuous flow of metal toward said casting housing;   operating said electronic management unit to adjust the speed of said rollers and the cooling water dispensed by said spraying system.   
     
     
         15 . The method according to  claim 14 , further comprising:
 step 1—with said gate fully closed and the level control device fully open, flowing molten metal inside said channels to said collection trays and monitoring a temperature of a metal bath;   step 2—upon the temperature of the metal bath rising above a threshold temperature, waiting for the metal to continue to flow and keeping its temperature constant for a specified time, and upon the temperature of the metal bath dropping below the threshold temperature during the waiting, further performing the flowing and monitoring of step 1;   step 3—closing said level control device to a preset position, so as to empty the bath to the point of interrupting the flowing of the molten metal;   step 4—upon said level control device reaching the preset position, waiting for the level of the metal bath to drop below a preset level, which must be lower than the level of the bath fluxing drain channels;   step 5—upon the level of the metal dropping below the preset level, reading the values of the main parameters that are significant for the line startup sequence, stored previously in a file, and using said parameters as set points of the line in the current startup step,   said parameters being sampled and recorded with a predefined interrupt time during recording, said samples being read and performed with the same interrupt time during execution, so as to faithfully repeat a previously performed startup process, one of said main parameters that is reproduced being the position of the gate, which is opened in steps by reproducing exactly the maneuvers performed by an operator in a sampled sequence performed manually;   at the same time, setting to automatic mode said level control device for metal level adjustment and actuating said level control device so that the level of molten metal remains at a value set in step 5;   opening the gate gradually, causing a gradual lowering of the level of the metal, and causing a gradual opening of the level control device in order to keep this level constant at the set value.   
     
     
         16 . The method according to  claim 15 , comprising, during the sampling steps, monitoring and recording the following line parameters:
 roller speed, roller cooling temperature, upper and lower roller water flow-rate, roller release agent translation speed and start.