Patents by Inventor Craig Lee Shaber

Craig Lee Shaber has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20250135527
    Abstract: Provided herein is a system and method for parameter value determination of direct chill casting using artificial intelligence. The system may employ one or more image sensors configured to capture images of a surface of a direct chill cast billet or ingot, where the images depict one or more casting anomalies. A first machine learning model configured to process images is configured to identify, within the images, casting anomalies along with metrics of the casting anomalies or anomalies can be directly input to the first machine learning model. The casting anomalies are identified by the first machine learning model, classified through conditional statements according to anomaly type and scale. A second machine learning model is configured to process the casting anomaly type and scale as an input along with most parameters and set-up conditions that can cause the anomaly to generate changes to parameter values of the direct chill casting process to reduce or eliminate the casting anomalies.
    Type: Application
    Filed: October 31, 2023
    Publication date: May 1, 2025
    Inventor: Craig Lee Shaber
  • Publication number: 20240226996
    Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.
    Type: Application
    Filed: December 6, 2023
    Publication date: July 11, 2024
    Inventors: Craig Richard CORDILL, Craig Lee SHABER, Michael Kim ANDERSON
  • Patent number: 11883876
    Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.
    Type: Grant
    Filed: April 7, 2022
    Date of Patent: January 30, 2024
    Assignee: WAGSTAFF, INC.
    Inventors: Craig Richard Cordill, Craig Lee Shaber, Michael Kim Anderson
  • Patent number: 11548061
    Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.
    Type: Grant
    Filed: June 18, 2021
    Date of Patent: January 10, 2023
    Assignee: WAGSTAFF, INC.
    Inventors: Craig Richard Cordill, Craig Lee Shaber, Michael Kim Anderson
  • Publication number: 20220226884
    Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.
    Type: Application
    Filed: April 7, 2022
    Publication date: July 21, 2022
    Inventors: Craig Richard CORDILL, Craig Lee SHABER, Michael Kim ANDERSON
  • Patent number: 11331715
    Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.
    Type: Grant
    Filed: June 11, 2018
    Date of Patent: May 17, 2022
    Assignee: WAGSTAFF, INC.
    Inventors: Craig Richard Cordill, Craig Lee Shaber, Michael Kim Anderson
  • Patent number: 11292051
    Abstract: Provided herein are an apparatus and method for continuous casting of metal, and more particularly, to an apparatus and method to reduce macrosegregation through a mechanism for controlling the position of a spout tip or diffuser during the casting process to maintain the spout tip or diffuser near the solidification front, location of transition between liquid metal and solid metal in the cast part. An apparatus may include: a mold frame supporting a mold defining a mold cavity; a liquid diffuser; and an actuator configured to move at least one of the mold frame and the liquid diffuser relative to one another, wherein the actuator is configured to move at least one of the mold frame and the liquid diffuser relative to one another in response to a signal from at least one sensor.
    Type: Grant
    Filed: January 6, 2021
    Date of Patent: April 5, 2022
    Assignee: WAGSTAFF, INC.
    Inventors: Bin Zhang, Craig Lee Shaber, Mike Anderson
  • Publication number: 20210308748
    Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.
    Type: Application
    Filed: June 18, 2021
    Publication date: October 7, 2021
    Inventors: Craig Richard CORDILL, Craig Lee SHABER, Michael Kim ANDERSON
  • Patent number: 11065678
    Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.
    Type: Grant
    Filed: May 29, 2019
    Date of Patent: July 20, 2021
    Assignee: WAGSTAFF, INC.
    Inventors: Craig Richard Cordill, Craig Lee Shaber, Michael Kim Anderson
  • Publication number: 20210154730
    Abstract: Provided herein are an apparatus and method for continuous casting of metal, and more particularly, to an apparatus and method to reduce macrosegregation through a mechanism for controlling the position of a spout tip or diffuser during the casting process to maintain the spout tip or diffuser near the solidification front, location of transition between liquid metal and solid metal in the cast part. An apparatus may include: a mold frame supporting a mold defining a mold cavity; a liquid diffuser; and an actuator configured to move at least one of the mold frame and the liquid diffuser relative to one another, wherein the actuator is configured to move at least one of the mold frame and the liquid diffuser relative to one another in response to a signal from at least one sensor.
    Type: Application
    Filed: January 6, 2021
    Publication date: May 27, 2021
    Inventors: Bin ZHANG, Craig Lee SHABER, Mike ANDERSON
  • Patent number: 10913108
    Abstract: Provided herein are an apparatus and method for continuous casting of metal, and more particularly, to an apparatus and method to reduce macrosegregation through a mechanism for controlling the position of a spout tip or diffuser during the casting process to maintain the spout tip or diffuser near the solidification front, location of transition between liquid metal and solid metal in the cast part. An apparatus may include: a mold frame supporting a mold defining a mold cavity; a liquid diffuser; and an actuator configured to move at least one of the mold frame and the liquid diffuser relative to one another, wherein the actuator is configured to move at least one of the mold frame and the liquid diffuser relative to one another in response to a signal from at least one sensor.
    Type: Grant
    Filed: September 12, 2017
    Date of Patent: February 9, 2021
    Assignee: WAGSTAFF, INC.
    Inventors: Bin Zhang, Craig Lee Shaber, Mike Anderson
  • Publication number: 20200101527
    Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.
    Type: Application
    Filed: June 11, 2018
    Publication date: April 2, 2020
    Inventors: Craig Richard CORDILL, Craig Lee SHABER, Michael Kim ANDERSON
  • Publication number: 20190275582
    Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.
    Type: Application
    Filed: May 29, 2019
    Publication date: September 12, 2019
    Inventors: Craig Richard CORDILL, Craig Lee SHABER, Michael Kim ANDERSON
  • Patent number: 10350674
    Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.
    Type: Grant
    Filed: June 12, 2017
    Date of Patent: July 16, 2019
    Assignee: WAGSTAFF, INC.
    Inventors: Craig Richard Cordill, Craig Lee Shaber, Michael Kim Anderson
  • Publication number: 20190076918
    Abstract: Provided herein are an apparatus and method for continuous casting of metal, and more particularly, to an apparatus and method to reduce macrosegregation through a mechanism for controlling the position of a spout tip or diffuser during the casting process to maintain the spout tip or diffuser near the solidification front, location of transition between liquid metal and solid metal in the cast part. An apparatus may include: a mold frame supporting a mold defining a mold cavity; a liquid diffuser; and an actuator configured to move at least one of the mold frame and the liquid diffuser relative to one another, wherein the actuator is configured to move at least one of the mold frame and the liquid diffuser relative to one another in response to a signal from at least one sensor.
    Type: Application
    Filed: September 12, 2017
    Publication date: March 14, 2019
    Inventors: Bin ZHANG, Craig Lee SHABER, Mike ANDERSON
  • Publication number: 20180354023
    Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.
    Type: Application
    Filed: June 12, 2017
    Publication date: December 13, 2018
    Inventors: Craig Richard CORDILL, Craig Lee Shaber, Michael Kim Anderson