Detecting metal separation from casting mold

Abstract

Metal can separate from a casting mold during the casting process. A detection system can monitor the mold and determine if the metal has separated from the mold. The detection system can include a camera, a light source, and a computer system. The camera and light source can be placed on opposite sides of the casting mold and positioned to both point toward the mold. The computer system can detect if any light is visible between the mold and the metal based on data received from the camera. The computer system can then determine the metal has pulled away from the mold based on the detected light.

1 . A system for detecting metal contraction in a mold, comprising:
 a mold for receiving and containing metal, the mold comprising a first side, a second side opposite the first side, and a plurality of walls spanning between the first side and the second side;   a camera facing the first side of the mold and having a field of vision including at least a portion of the first side of the mold;   a light source facing the second side of the mold for emitting light directed toward the second side of the mold, the emitted light visible to the camera through the first side of the mold when the metal is separated from at least one of the plurality of walls;   wherein the system is configured to:
 detect light visible between the at least one of the plurality of walls and the metal based at least in part on data from the camera; and 
 determine whether separation of the metal from the at least one of the plurality of walls has occurred based at least in part on the light detected as visible between the at least one of the plurality of walls and the metal. 
   
     
     
         2 . The system of  claim 1 , wherein the first side of the mold is an open top for receiving the metal and the second side of the mold is an open bottom allowing the metal to exit the mold or wherein the first side of the mold is an open bottom allowing metal to exit the mold and the second side of the mold is an open top for receiving the metal. 
     
     
         3 . The system of  claim 1 , wherein the mold is a first mold and the field of vision of the camera includes the first mold and a second mold such that the system can detect separation of the metal from at least one of the plurality of walls in either or both of the first mold and the second mold and wherein the system is further configured to send a response based at least in part on determining whether separation of at least one of the plurality of walls and the metal has occurred. 
     
     
         4 . The system of  claim 1 , wherein the light source is a plurality of light emitting diodes capable of emitting light at a wavelength of 380 to 740 nm. 
     
     
         5 . The system of  claim 1 , further comprising a container positioned above the mold having a bottom and defining a channel for containing the metal, the bottom of the container defining one or more apertures for flow of the metal from the container to the mold, wherein the system is further configured to adjust the flow of the metal from the container to the mold based at least in part if it is determined that separation of at least one of the plurality of walls and the metal has occurred. 
     
     
         6 . The system of  claim 5 , wherein the camera is a first camera and the system further comprises a second camera with a field of vision that differs from the field of vision of the first camera, and wherein detecting whether light is visible between at least one of the plurality of walls and the metal is based on data from one or both of the first camera or the second camera. 
     
     
         7 . The system of  claim 6 , wherein the mold is a first mold and the system further comprises a second mold comprising a first side, a second side opposite the first side, and a plurality of side walls spanning between the first side and the second side, wherein the second camera has a field of vision that includes the first side of the second mold, wherein the system is further configured to detect whether light is visible between at least one of the plurality of side walls of the first mold and the metal based at least in part on data from the first camera and whether light is visible between at least one of the plurality of side walls of the second mold and the metal based at least in part on data from the second camera. 
     
     
         8 . (canceled) 
     
     
         9 . The system of  claim 1 , wherein the system further comprises a launder positioned above the mold and configured for depositing the metal into the mold, the launder defining a channel for receiving the metal and comprising a flow control device configured to control a flow rate of the metal into the mold. 
     
     
         10 . The system of  claim 9 , wherein the system is further configured to control the flow rate of the metal into the mold based on at least determining whether separation of at least one of the plurality of walls and the metal has occurred. 
     
     
         11 . (canceled) 
     
     
         12 . The system of  claim 5 , wherein adjusting the flow of the metal from the channel to the mold further comprises:
 determining a size of the separation between at least one of the plurality of walls and the metal;   comparing the size of the separation to a threshold value; and   increasing the flow of the metal if the size of the separation is less than the threshold value or stopping or decreasing the flow of the metal if the size of the separation is greater than the threshold value.   
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . The system of  claim 9 , wherein the flow control device comprises at least one of a pin, a valve, a stop, or a funnel. 
     
     
         16 . A method for detecting metal separating from a mold, the method comprising:
 causing the metal to be received into the mold, the mold comprising a first face, a second face opposing the first face, and a plurality of side walls spanning between the first and second faces, where at least one of the plurality of side walls contacts the metal;   detecting if light is present between at least one of the plurality of side walls of the mold and the metal based on at least data received from a camera having a field of view of at least a portion of the first face, a light source emitting the light and positioned adjacent to the second face and directing the light towards the second face; and   determining if the metal has pulled away from at least one of the plurality of side walls of the mold based on at least detecting if the light is present.   
     
     
         17 . The method of  claim 16 , further comprising sending a response based on at least determining the metal has pulled away from at least one of the plurality of side walls of the mold. 
     
     
         18 . (canceled) 
     
     
         19 . The method of  claim 16 , wherein causing the metal to be received into the mold comprises operating a flow control device configured for depositing the metal into the mold, the flow control device operable to change a flow rate of the metal into the mold. 
     
     
         20 . The method of  claim 19 , further comprising operating the flow control device to adjusting the flow rate of the metal into the mold based on at least determining the metal has pulled away from at least one of the plurality of side walls of the mold. 
     
     
         21 . The method of  claim 20 , wherein adjusting the flow rate of the metal into the mold comprises: determining a size of a separation between at least one of the plurality of side walls and the metal; comparing the size of the separation to a threshold value; and increasing the flow rate of the metal if the size of the separation is less than the threshold value or stopping or decreasing the flow rate of the metal if the size of the separation is greater than the threshold value. 
     
     
         22 . (canceled) 
     
     
         23 . The method of  claim 16 , further comprising:
 identifying colors of environmental light in an environment outside of the mold based on data from the camera or data from a light sensor disposed in the environment outside of the mold; and   controlling the light source to generate light with a color or colors that differ from the identified colors.   
     
     
         24 . The method of  claim 16 , wherein detecting light between at least one of the plurality of side walls of the mold and the metal further comprises receiving data from a second camera having a field of view of at least a portion of the first face of the mold. 
     
     
         25 . The method of  claim 16 , wherein detecting light between at least one of the plurality of side walls of the mold further comprises moving the camera to change the field of view. 
     
     
         26 . (canceled) 
     
     
         27 . The method of  claim 16 , wherein determining the metal has pulled away from at least one of the plurality of side walls of the mold is further based on information received about the mold or the metal.