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.

Description

CROSS REFERENCE TO RELATED APPLICATION

The present application claims the benefits of U.S. Provisional Application Ser. No. 62/349,463, filed Jun. 13, 2016, of the same title, which is incorporated herein by this reference in its entirety.

FIELD

The disclosure relates generally to continuous casting and particularly to automated or partially automated continuous casting systems.

BACKGROUND

Continuous casting uses traveling endless molds (e.g., rolls, belts, and/or wheels) having zero or substantially zero relative movement between the mold and casting surfaces. Most moving molds provide a high cooling rate due to a very small air gap between the mold and casting surface.

FIG. 1 shows a prior art block caster 100. In a block caster, a molten metal poured into a launder 104 is fed from a headbox or tundish 108 through a ceramic nozzle 112 into the space between opposing and counter-rotating chains 114a and 114b of metal chilling blocks 118 traveling on caterpillar-like tracks 122. The blocks 118 are cooled by chillers 126, which in turn cool and solidify the melt in the space between the opposing chilling blocks. Adjacent blocks contact (or nearly contact) each other to prevent or inhibit penetration of liquid metal into any inter-block gap to avoid or minimize the formation of block joints in the surface of the cast strip 130. The cast strip 130 is pulled out by a withdrawal unit (not shown) synchronized with the sprocket drive 134 of the blocks. When adjacent chilling blocks fail to define a planar surface contacting the cast strip, a surface impression of the joint between the blocks, known as a block joint, can form on the cast strip 130 due to relative position or (e.g., the chilling block is made level before startup but is rarely perfectly flush and there is movement during caster operation) movement of adjacent blocks from heating and cooling cycles in response to contact with molten metal. A typical block joint impression, due to an offset, irregularity, or step up or down, in adjacent chilling block surfaces, has a height of up to about 300 microns, more typically from about 5 to about 100 microns, and more typically from about 10 to about 75 microns above the surrounding surface of the cast strip and can render the cast strip unsuitable for many applications, including automotive exterior panels due to post-painting visibility. As will be appreciated, the cast strip adjacent to the face of a chilling block (and away from the inter-block joints) generally has significantly fewer, if any, surface irregularities.

FIG. 2 shows a prior art twin-belt caster 200. Molten metal is fed from the ceramic nozzle 112 through the gap between two counter-rotating belts 204a and 204b under tension. The belts are cooled by water jets 208 from a side opposite the surface contacting the cast strip 130. The cooled belts cool and solidify the melt between the belts. Back-up rolls 212 maintain a substantially planar surface of the belt contacting the cast strip 130. The cast strip 130 is pulled out by a withdrawal unit (not shown) synchronized with the sprocket drive 216 of the blocks. A common surface defect in cast strip manufactured by belt casters is an impression of the belt seam. A typical belt seam impression has a height of up to about 125 microns, more typically from about 5 to about 100 microns, and more typically from about 10 to about 75 microns above the surrounding surface of the cast strip and can render the cast strip unsuitable for many applications, including automotive exterior panels due to post-painting visibility. A depression on the back side of a belt caster can pulse the entire belt, much like an Indian smoke signal blanket. Belt casters can have a depression from grinding the weld joint below flush. A surface defect can also result from a bad caster stop event.

Other continuous casting systems include without limitation single-roll casters, twin-roll casters, and rotary casters.

Periodically, components, such as blocks and back-up rolls, need to be repaired or replaced due to the effects of wear or damage. Component repair or replacement often require the caster to be shut down, with concomitant loss of cast strip production. The economic cost of lost cast strip production can be substantial depending on caster down time.

There is therefore a need to repair or replace caster components during caster operation or without interrupting caster operation.

SUMMARY

These and other needs are addressed by the various aspects, embodiments, and/or configurations of the present disclosure. The present disclosure is directed to automated monitoring and/or adjustment of a casting system or assembly, thereby enabling repair and/or replacement of caster components during caster operation or without interrupting caster operation.

A casting system can include:

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 a reference position and/or 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 provide the adjustment amount and/or direction to an operator for adjustment of the second casting system component and/or command that the second casting system component be adjusted by the adjustment amount and/or direction.

The casting system can be a block caster. In that case, the first, second, and third casting system components are first, second, and third chilling blocks. The second chilling block can be adjusted by one or more adjustment points on the second chilling block. The first chilling block can be disengaged and removed from a track guide supporting chilling blocks of the casting system. The second casting component can be positioned in a position formerly occupied by the first chilling block and engaged with the track guide.

The sensors can be one or more of a laser radar detector, a mechanical displacement device, an imaging device, an optical 3d measuring system, and an ultrasound transducer.

The replacing, sensing, determining, providing, and/or commanding operations can occur while the casting system is casting a metal or metal alloy.

The molten metal or metal alloy is commonly one or more of manganese, a manganese alloy, aluminum, an aluminum alloy, copper, a copper alloy, iron, and an iron alloy.

The microprocessor executable control system can select the second casting component from among multiple possible casting components to replace the first casting component.

The casting component changer can be one or more of a robotic arm, a boom, a push arm or piston, and a pull arm or piston.

The multiple possible casting components can be positioned in multiple cartridges. The first casting component, when removed, can be positioned in a cartridge.

The replacing operation can include 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.

The replacing operation can include 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.

The casting system can further include:

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.

The casting assembly can include one or more of a single-belt caster, twin-belt caster, single-roll caster, twin-roll caster, and rotary caster.

The casting assembly component can alternatively be one or more of a roller, belt, back-up roll, and block belt.

The microprocessor executable control system can adjust 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 casting assembly component.

The present disclosure can provide a number of advantages depending on the particular aspect, embodiment, and/or configuration. The casting system can identify a casting system component requiring replacement and enable automatic or semi-automatic component replacement and adjustment of the replacement casting system component, during casting system operation, to inhibit, remove, or reduce the formation of surface defects in a next casting cycle (e.g., next revolution of a roll, block or belt caster). This can eliminate the need not only for manual block adjustment but also for shutting down the casting system to replace a casting system component and reset an improperly adjusted replacement casting system component. This has the further benefit of making less expensive continuously cast strip applicable to a broader variety of applications and markets.

These and other advantages will be apparent from the disclosure.

As used herein, “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. When each one of A, B, and C in the above expressions refers to an element, such as X, Y, and Z, or class of elements, such as X₁-X_n, Y₁-Y_m, and Z₁-Z_o, the phrase is intended to refer to a single element selected from X, Y, and Z, a combination of elements selected from the same class (e.g., X₁ and X₂) as well as a combination of elements selected from two or more classes (e.g., Y₁ and Z_o).

The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.

“Aluminum alloys” are alloys in which aluminum (Al) is the predominant metal. The typical alloying elements are copper, magnesium, manganese, silicon, and zinc.

The term “automatic” and variations thereof, as used herein, refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be “material”.

The term “computer-readable medium” as used herein refers to any storage and/or transmission medium that participate in providing instructions to a processor for execution. Such a computer-readable medium is commonly tangible, non-transitory, and non-transient and can take many forms, including but not limited to, non-volatile media, volatile media, and transmission media and includes without limitation random access memory (“RAM”), read only memory (“ROM”), and the like. Non-volatile media includes, for example, NVRAM, or magnetic or optical disks. Volatile media includes dynamic memory, such as main memory. Common forms of computer-readable media include, for example, a floppy disk (including without limitation a Bernoulli cartridge, ZIP drive, and JAZ drive), a flexible disk, hard disk, magnetic tape or cassettes, or any other magnetic medium, magneto-optical medium, a digital video disk (such as CD-ROM), any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, a solid state medium like a memory card, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read. A digital file attachment to e-mail or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. When the computer-readable media is configured as a database, it is to be understood that the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Accordingly, the disclosure is considered to include a tangible storage medium or distribution medium and prior art-recognized equivalents and successor media, in which the software implementations of the present disclosure are stored. Computer-readable storage medium commonly excludes transient storage media, particularly electrical, magnetic, electromagnetic, optical, magneto-optical signals.

The term “continuous casting” or “strand casting” refers to the process whereby molten metal is solidified into a “semifinished” billet, bloom, or slab for subsequent rolling in the finishing mills. Continuous casting is often used to cast aluminum, magnesium, and copper alloys and steel.

The terms “determine”, “calculate” and “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation, algorithm, or technique.

The term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112, Paragraph 6. Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials or acts and the equivalents thereof shall include all those described in the summary, brief description of the drawings, detailed description, abstract, and claims themselves.

The term “module” as used herein refers to any known or later developed hardware, software, firmware, artificial intelligence, fuzzy logic, or combination of hardware and software that is capable of performing the functionality associated with that element.

Unless otherwise noted, all component or composition levels are in reference to the active portion of that component or composition and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.

All percentages and ratios are calculated by total composition weight, unless indicated otherwise.

Unless otherwise noted, all component or composition levels are in reference to the active portion of that component or composition and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.

All percentages and ratios are calculated by total composition weight, unless indicated otherwise.

The preceding is a simplified summary of the disclosure to provide an understanding of some aspects of the disclosure. This summary is neither an extensive nor exhaustive overview of the disclosure and its various aspects, embodiments, and/or configurations. It is intended neither to identify key or critical elements of the disclosure nor to delineate the scope of the disclosure but to present selected concepts of the disclosure in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other aspects, embodiments, and/or configurations of the disclosure are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below. Also, while the disclosure is presented in terms of exemplary embodiments, it should be appreciated that individual aspects of the disclosure can be separately claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present disclosure. These drawings, together with the description, explain the principles of the disclosure. The drawings simply illustrate preferred and alternative examples of how the disclosure can be made and used and are not to be construed as limiting the disclosure to only the illustrated and described examples. Further features and advantages will become apparent from the following, more detailed, description of the various aspects, embodiments, and configurations of the disclosure, as illustrated by the drawings referenced below.

FIG. 1 depicts a prior art block casting system;

FIG. 2 depicts a prior art twin-belt casting system;

FIG. 3 depicts a partial top view of a block casting system according to an embodiment of this disclosure;

FIG. 4 depicts a partial side view of a block casting system according to an embodiment of this disclosure;

FIG. 5A is a top view of a chilling block according to an embodiment;

FIG. 5B is a side view of a chilling block according to an embodiment;

FIG. 6 is a partial side view of a block casting system according to an embodiment of this disclosure;

FIG. 7 is a partial top view of a block casting system according to an embodiment of this disclosure;

FIG. 8 is a side view of a block carrying system according to an embodiment of this disclosure;

FIG. 9 is a side view of a block according to an embodiment of this disclosure;

FIG. 10 is a flow chart of control logic according to an embodiment; and

FIG. 11 is a side view of a modified block caster according to an embodiment.

DETAILED DESCRIPTION

FIGS. 3, 4, and 6 depict an embodiment of a block casting system 300 according to this disclosure. The block casting system has upper and lower sets 304 of chilling blocks 316, each engaged with a corresponding endless or continuous track guide 608, to cool and solidify the molten metal into a cast strip 130, plural sensors 308 located above and below, respectively, each set of upper and low chilling block sets 304 to detect chilling block surface irregularities (e.g., steps, offsets, and other interruptions in the surface planes of adjacent chilling blocks which typically occur at inter-block joints 320 as shown in FIG. 4 (the solid line refers to the joint 320 between adjacent chilling blocks 316 in the upper set 304a of chilling blocks and dashed lines refer to the joints 320 between adjacent chilling blocks in the lower set 304b of chilling blocks)) and belt seams, and an adjustment control module 312, in communication by control lines 324 with the sensors and adjustment components in the chilling blocks 316, to receive measurements and provide user recommendations or automatic commands to adjust the blocks 316 appropriately to increase adjacent chilling block surface planarity and thereby substantially minimize or inhibit formation of surface defects in the cast strip.

Surface defects removed, inhibited, or otherwise reduced in frequency by the block casting system 300 can vary depending on the casting technology employed. Surface defects in continuously cast strip include, for example, impressions left by block joints and belt seams, streaks, drag marks, protrusions, channels, valleys, crystallites, films (such oxide films), impurities, or combinations thereof. While not wanting to be limited by theory, the defects can be caused by one or more of the rollers, belts, and blocks of the caster and can be addressed by replacing and/or adjusting one or more of the position, orientation, application force or pressure (applied to the cast strip), and the like of the roller, belt, or block.

While FIGS. 3 and 4 depict the control system with respect to the upper set of chilling blocks, it is to be understood that a similar system is used to monitor and adjust the lower set of chilling blocks.

Referring to FIGS. 3-4, 5A and 5B, and 6 each chilling block 316 in the upper and lower sets 304 of chilling blocks, which are positioned on one of the opposing sides of the cast strip 130, includes multiple adjustment points or adjustment devices 328 (hereinafter “adjustment points”), typically located at or near each joint 320. Although the adjustment points 328 can be any device able to move the chilling block upwardly and/or downwardly at the adjustment point's respective location (as shown by the arrows in FIGS. 5A and 5B), examples of adjustment points 328 include coarse and/or fine adjustment screws, differential adjusters, sub-micron adjustors, hydraulic actuators, and other adjustment mechanisms.

As shown in FIGS. 5A and 5B, the adjustment points 328 can be distributed at selected locations in a matrix or grid pattern. Adjustment points 328a-f are laid out along line 500 and adjustment points 328g-1 along parallel line 504. Pairs of adjustment points are further laid out along lines orthogonal to parallel lines 500 and 504, specifically adjustment points 329a and g are laid out along line 508, adjustment points 329b and h are laid out along line 512, adjustment points 329c and i are laid out along line 516, adjustment points 329d and j are laid out along line 520, adjustment points 329e and h are laid out along line 524, and adjustment points 329f and i are laid out along line 528.

To enable the control system 312 to address independently each adjustment point, each adjustment point is assigned a unique identifier relative to the other adjustment points. Although any type of identifier can be employed, the identifier in one embodiment has a first unique identifier “X” corresponding to an identifier of the upper or lower set of chilling blocks of which the selected chilling block 316 is a member, a second identifier “Y” (which may be non-unique relative to another chilling block in the other set of chilling blocks but is unique within the set of chilling blocks of which the selected chilling block is a member) corresponding to an identifier of the particular chilling block to be adjusted by the selected adjustment point, and a third identifier “Z” (which may be non-unique relative to another adjustment point in another chilling block in the upper or lower sets of chilling blocks 304 but is unique within the corresponding chilling block 316 on which the selected adjustment point is located) is an identifier corresponding to the selected adjustment point.

The sensors 308 can be any device able to detect surface irregularities in the cast strip-contacting surfaces of the upper and lower chilling block sets 304. Examples include a laser radar detector (which uses a laser beam 350 to determine the distance from the sensor to the block surface), mechanical displacement device (which measures the vertical variations in travel or movement of a wheel or other contact device with the block surface), imaging device (which uses image processing to identify surface irregularities and other variations in block surface topology, such as image processing based on the block surface images captured by still pictures or video images captured as described in U.S. Pat. No. 4,539,561 (which is incorporated herein by this reference)), optical 3d measuring system (which uses triangulation to determine the spatial dimensions and the geometry of the block surface), and ultrasound transducer (which uses an ultrasound transducer to emit ultrasonic energy and ultrasonic time-of-flight methods to measure distance from the sensor to the chilling block surface). Laser radar, for example, can operate on the time of flight principle by sending a laser pulse in a narrow beam towards the chilling block surface to be measured and measuring the time taken by the pulse to reflect off the target chilling block surface and return to the sender. Other laser radar distance measuring technologies include multiple frequency phase-shift (which uses an intensity modulated beam to measure the phase shift of multiple frequencies on reflection of electromagnetic energy by the target chilling block surface and then solves various simultaneous equations to yield a final distance measure from the sensor to the target chilling block surface), frequency modulation (which use modulated laser beams, for example, with a repetitive linear frequency ramp by which the distance to be measured from the sensor to the target chilling block surface is translated into a frequency offset) and interferometry (which measures changes in distance between the sensor and the target chilling block surface rather than absolute distances). Due to the high temperatures of the cast strip, non-contact sensors, such as laser radar, imaging devices, optical 3d measuring systems, and ultrasound systems, are generally employed.

As in the case of the adjustment points 328, each sensor has a unique (relative to the other sensors) sensor identifier. The sensor identifier can be as simple as a combination of a generic sensor identifier (indicating that the signal originates at a sensor) and a number of the sensor (indicating that sensor 1 for example originated the signal). In another example, the sensor identifier can be a combination of a first indicator (indicating whether the sensor is located in the upper or lower set of chilling blocks (e.g., above or below the cast slab 130)) and a second identifier indicating which sensor of the corresponding set of upper or lower sensors originated the signal).

The geometry of the block casting system 300 can be important. Referring to FIG. 3, the centers of the adjustment points and centers of the corresponding sensor can be located in or along a common plane. By way of example, as shown in FIG. 3 the centers of the top row of adjustment points 328 and respective sensor 308 can lie in plane 360, the centers of the next row of adjustment points 328 and respective sensor 308 can lie in plane 364, the centers of the next row of adjustment points 328 and respective sensor 308 can lie in plane 368, the centers of the next row of adjustment points 328 and respective sensor 308 can lie in plane 372, the centers of the next row of adjustment points 328 and respective sensor 308 can lie in plane 376, and the centers of the next row of adjustment points 328 and respective sensor 308 can lie in plane 378. The centers of the upper and lower sets of sensors 308 (the upper set of sensors 308 corresponding to the upper set of chilling blocks and the lower set of sensors 308 corresponding to the lower set of chilling blocks) can lie in a common plane 382.

Each of the upper and lower sets of chilling blocks has separate adjustment and measurement zones 392 and 396 controlled by separate or a common adjustment control system 312. Referring to FIG. 4, the distance 388 between the adjustment 392 and measurement zones 396 for each of the upper and lower sets of chilling blocks is selected such that the chilling block currently in the upper or lower adjustment zone 392 corresponds to a set of distance measurements previously taken in the corresponding upper or lower measurement zone 396 by the respective sensor 308. In some applications, each adjustment zone 392 is located before the cooler 126. In other applications, each adjustment zone 392 is located after the cooler 126. In yet other applications, each adjustment zone 396 is located before and/or after the cooler 126 (which location can be differently selected for the upper versus the lower chilling block sets). The measurement zone 396 is commonly located before the cooler 126 but can alternatively or additionally be located after the cooler 126. FIG. 6 depicts a casting system configuration in which the measurement zone 308 is located before the cooler 126 and the corresponding adjustment zone 392 is located after the cooler 126. The distance 388 is typically a function of one or more of the speed of displacement of the cast strip 130, the rate of rotation of the sprocket drive 216, chilling block 316 width, and the number of chilling blocks 316 in each of the upper and lower sets of chilling blocks. If the adjustment zone were located entirely after the cooler, the cooler would be modified to accept excessively non-flush conditions. If part of the adjustments, or the rough adjustments, were performed before the cooler and the final finer adjustments made after the cooler, cooler performance would not be substantially impacted adversely and the cooler would not need to be redesigned.

Prior to discussing the chilling block replacement operation of the block casting system 300, it is important to understand the operation of the block casting system 300 in manufacturing cast strip 130. As can be seen from FIG. 3, the inter-block joints 320 of the blocks in contact with the upper surface of the cast strip 130 and adjustment points are offset in the direction of cast strip travel from the inter-block joints 320 and adjustment points of the blocks in contact with the lower surface of the cast strip 130. In this manner, the inter-block joint surface irregularities in adjacent chilling blocks commonly alternate between the upper and lower cast strip surfaces as the cast strip moves through the measurement and adjustment zones 396. As can be further seen in FIG. 1, the upper and lower chilling blocks 316 and inter-block joints 320 move in a common direction when in contact with the cast strip.

Each of the upper and lower sets of chilling blocks has a corresponding block changer 604 (FIG. 6) to slide, rotate, lift, or translate an old chilling block out of position on the track guide 608 and slide, rotate, lift, or translate, as appropriate, a new chilling block into old block's position on the track guide. The block changer 604 can be any device suitable for these operations, such as a robotic arm, a boom, and a push or pull (e.g., telescopic) arm or piston. Mechanical displacement mechanisms for a push or pull arm of piston include, without limitation, a ratchet mechanism (e.g., pawl and ratchet), a gear, cogwheel or sprocket mechanism (e.g., two or more meshing gears, such as spur gear(s), helical gear(s), double helical gear(s), bevel gear(s), spiral bevel gear(s), hypoid gear(s), crown gear(s), worm gear(s), non-circular gear(s), rack and pinion gear(s), epicyclic gear(s), sun and planet gear(s), harmonic gear(s), cage gear(s), and magnetic gear(s)). Other displacement mechanisms include, without limitation, hydraulic, electromechanical, and electromagnetic mechanisms.

FIGS. 7-9 depict an embodiment of a block changing system 700. The block changing system 700 includes a block changer 604, set of new blocks 704, and set of old (or previously replaced) blocks 708. The sets of new and old blocks are positioned on either side of the set of upper or lower chilling blocks 304, which are in operation producing cast strip 130. Alternatively, the sets of new and old blocks can be positioned on a common side of the set of upper or lower chilling blocks 304. When a selected one of the set of upper or lower chilling blocks 304 is to be replaced, the block is disengaged from the track guide 608, a new block 316 pushed by the block changer 604 from the set of new blocks 704 against the selected one of the set of upper or lower chilling blocks, thereby displacing it from its disengaged operating position on the track guide and moving it to the set of old blocks. When the new block is in the disengaged operating position on the track guide, it is engaged with the track guide to place or lock it in operating position for casting the cast strip 130. The selected one of the upper or lower chilling blocks 708 can be guided out of the disengaged operating position by an integral rail or track or other guidance system. Although the selected one of the set of upper or lower chilling blocks 708 is shown as being displaced out of position by contact with the new block 316, the selected one of the upper or lower chilling blocks 708 can be moved out of the operating position and the new block moved into the same operating position with no inter-block contact.

To facilitate block exchange, a cartridge system can be employed. The replaced block can be slid out of disengaged operating position into an empty receiving cartridge (not shown). The now occupied receiving cartridge is then moved away from the upper or lower set of chilling blocks and a new empty receiving cartridge moved into alignment with the next selected one of the set of upper or lower chilling blocks 708 to be replaced. Likewise, the new block can be moved out of a receiving cartridge (not shown) and into the disengaged operating position followed by movement of the now empty receiving cartridge away from the upper or lower set of chilling blocks. Receiving cartridges assist in positioning and aligning the new blocks with the selected one of the set of upper or lower chilling blocks 708 to be replaced and removing the replaced block. The next cartridge containing a new block is moved into alignment with the next selected one of the set of upper or lower chilling blocks 708 to be replaced and the process repeated. In one configuration, the cartridges are on a common carrier positioned on a common side of the set of upper or lower chilling blocks. With both old and new blocks on the common side, the block changer moves new blocks and empties cartridges and moves replaced blocks into the now emptied cartridges.

As will be appreciated, the two block cartridges (i.e., empty cartridge to receive the replaced block and cartridge containing the new block) each need to be aligned simultaneously with the chilling block to be replaced and move synchronously with (e.g., move at the same speed as) the chilling block to be replaced to enable continuous and uninterrupted caster operation. This can be effected by connecting or engaging the cartridges with the track guide. An example of this type of system is shown in FIG. 8. Old or new blocks 316 are positioned on a carrier structure 800 having one or more rotatable supports 804 to enable the carrier structure 800 to move back and forth in response to movement of a translation mechanism 808. The translation can be hydraulic, mechanical, electrical, electromagnetic, or electromechanical. In the depicted translation mechanism 808, a hydraulic pump 812 moves a telescopic hydraulic cylinder 816 engaged with a connector 820 on the carrier structure forward in response to movement with the selected one of the set of upper or lower chilling blocks and backward after block replacement to position to replace a next block. As will be appreciated, other carrier structures can be employed depending on the application.

In another configuration, one or more robotic arms is/are employed. A first robotic arm engages the selected one of the set of upper and lower chilling blocks to be replaced and follows the selected block as the caster is moving. A second robotic arm pulls a new block from a rack, the selected block is disengaged from the track guide, the first robotic arm moves the selected block from the disengaged operating position to a rack, while the second robotic arm places the new block into the disengaged operating position. Then, the new block is engaged with the track guide.

The engagement and disengagement of the selected block with and from the track guide can be by any suitable mechanism. Referring to FIG. 9, one or more adjustment points 328 of a chilling block include an inward or outward facing pin 900 that releasably engages a hole or slot in a connector (not shown) on the track guide. The pin engages the connector when the block is in the engaged operating position and does not engage the connector when the block is in the disengaged operating position. The track guide can include one or more channels (not shown) along which the downwardly protruding ends 904 of the adjustment points 328 are guided in response to movement of the chilling block. Other non-limiting examples of engagement/disengagement mechanisms include a pin on the track guide connector that engages a hole or slot in the protruding end 904 of the adjustment point 328, moveable members on the track guide that engage and disengage a hole or slot in the block 316, moveable members on the block 316 that engage and disengage a hole or slot in the track guide, a pawl and ratchet mechanism, spring-loaded mechanisms, and the like.

FIG. 11 shows a circular block caster 1100 that is a combination of a roll caster and block caster. As can be seen from FIG. 11, each of the upper and lower sets of chilling blocks 1104a and b includes a plurality of chilling blocks 1108 engaging a central mandrel 1112. The upper and lower faces of each chilling block are arcuately shaped. Each of the upper and lower sets of chilling blocks are cooled by a cooler 1116. Each of the chilling blocks 1108 can be independently and selectively replaced and adjusted in any manner, including by the techniques disclosed above.

The operation of the adjustment control system will now be discussed with reference to FIG. 10.

In step 1000, the adjustment control system 312 selects a chilling block in one of the sets of upper and lower chilling blocks to be replaced. The selection can be based on user input and/or parameters sensed by one or more sensors. For example, consistently sensing a surface defect in a portion of a cast strip contacted by a given block indicates that the block is damaged or worn and requires replacement. The sensing can be based on a vision or dimension defect on the cast strip. When such a defect is sensed, the responsible chilling block (in the set of upper and lower set of chilling blocks casting the defect-containing upper or lower cast strip surface) is identified, such as by determining a rate of advance of the cast strip and/or rate of rotation of the chilling blocks and, based on the distance traversed by the cast strip during the time interval since the defect was first or last contacted with a chilling block and ending when the defect was sensed, determining the chilling block located at that distance along the face of the block caster. The defect can be sensed by any of the sensors identified above. The sensors can be the same as or in addition to the sensors providing feedback to control chilling block adjustment.

In step 1004, the adjustment control system 312 determines the selected chilling block's dimensions. This can be done by any technique, including user input or a look up table mapping the identity of the selected block against one or more dimensions (e.g., length, width, and/or thickness) of the block. A robotic arm can measure one or more dimensions of the selected block. As will be appreciated, a non-contact device can remain stationary and timely measure the dimensions.

In step 1008, the adjustment control system 312 selects a new or replacement chilling block having one or more similar dimension(s). This can be done by any technique, including user input or a look up table mapping the positions of the replacement blocks against one or more dimensions (e.g., length, width, and/or height) of the block. A robotic arm can measure one or more selected dimensions of each of the replacement blocks and select that replacement block having the closest selected dimension(s).

In step 1012, the adjustment control system 312 aligns the selected replacement block with the selected block to be replaced and replaces the selected block. A look up table can be updated to reflect one or more dimension(s) of the replacement block for the block dimensions of the corresponding block operating position in the set of upper or lower chilling blocks. Optionally, the adjustment control system 312 can, based on the difference between the thicknesses of the replaced block and the replacement block, effect rough adjustments to form a substantially planar surface with adjacent chilling blocks. The system should be able to handle the entire range of block dimensions. It is possible, however, to design a block casting system in which all of the blocks are relatively close in dimension (particularly when the expansion and contraction of thermal heating and cooling events occurs).

In step 1016, the adjustment control system 312 selects a sensor corresponding to a selected adjustment point in the measurement zone. The control system can identify a set of adjustment points for the replacement chilling block and/or inter-block joint entering the adjustment zone in many ways. In one technique, a position of a selected chilling block and/or inter-block joint is synchronized in computer readable memory with movement of one or both of the upper and lower sets of chilling blocks 304a and 304b (or the upper and lower track guides in the case of a belt caster). Based on this monitored location, the locations of the other chilling block and/or inter-block joints are readily determined (as the chilling blocks have known widths and/or are in a predictable constant sequence as the supporting track guide moves through each revolution). The control system 312 selects a sensor set corresponding to one or more selected adjustment point(s) (such as adjacent and opposing adjustment point(s) on either side of a selected inter-block joint (or other casting component) entering, departing, or currently in the adjustment zone 392). The sensor set, for example, when the selected adjustment point(s) is/are adjustment point 328a and 328b (or other casting component) is sensor 308a.

In step 1020, the control system 312 receives measurements from the selected sensor and determines a distance to the replacement block surface. The control system 312, as will be appreciated, can query the selected sensor for a set of readings or receive multiple sets of sensor readings from all sensors and select the appropriate set of readings, based on the identities of the source sensor. The selected set of sensor readings can enable the control system 312 to determine the distance at the point of measurement.

In step 1024, the control system 312 compares the measured distance to a predetermined or reference distance and/or a distance measured to a portion of the block surface of an adjacent block and, in decision diamond 1028, determines whether or not to adjust the selected adjustment point(s). When an absolute value of a difference in the measured distance from the predetermined or reference distance is at least a predetermined threshold, the control system 312 proceeds to step 1032. Alternatively, the control system 312 can determine a difference of the measured distance from a distance measured by a prior set of sensor readings from the selected sensor for an adjustment point (or a portion of the block surface of an adjacent block) in the same plane and/or a distance measured by one or more adjacent sensor(s) in one or more adjacent plane(s). When an absolute value of a delta between the determined difference and a predetermined difference is at least a predetermined threshold, the control system 312 proceeds to step 1032.

In step 1032, the control system 312 determines an adjustment amount and direction (e.g., up or down and either commands the selected adjustment point(s) to be adjusted (by a control signal addressed to the unique identifier of the adjustment point) to the determined adjustment amount and direction or recommends to a human user the adjustment amount and direction for manual adjustment of the adjustment point by the user (such as by the user pressing an actuator to cause movement up or down of the block in response to adjustment point activation). When automatic adjustment is performed, one or both of the opposing adjustment points on either side of the inter-block joint can be adjusted in a manner to maintain the step height over the inter-block joint 320 at or less than a predetermined magnitude. The target adjustment amount may be equivalent to the difference between the measured distance on either side of the inter-block joint 320 or a fraction or percentage thereof. The adjustment points can thus be adjusted in the same direction and by the same amount or by different amounts that sum up to the desired adjustment amount. Alternatively, the distance on either side of the inter-block joint can be measured and each adjustment point on either side of the joint adjusted to produce a substantially identical distance at its respective location.

After step 1032 or when no adjustment is required, the control system, in decision diamond 1036 determines whether there is an adjustment point or set of adjustment points in the adjustment zone. For example, when an inter-block joint is in the adjustment zone the preceding step must be repeated for each adjustment point adjacent to the inter-block joint.

When a further adjustment point(s) for the inter-block joint remains to be considered for adjustment, the control system returns to step 1016.

When no further adjustment points for the inter-block joint remain to be considered for adjustment, the control system returns to step 1000.

The disclosure can apply to detection of and/or continuous casting component replacement and adjustment and inhibit surface defects other than impressions left by block joints. For example, the disclosure can apply to any of the surface defects discussed above.

The disclosure can apply to automatic replacement and adjustment of components in other continuous casting techniques, such as twin-belt casters, single-roll casters, twin-roll casters, and rotary casters. In belt casters, for instance, the casting component to be replaced and adjusted can be the back-up rolls 212 so as to maintain a substantially planar surface of the belt contacting the cast strip 130. In a belt caster, there can be dimension defects on any of the back-up rolls behind the belt. Flat spots can occur when the caster is stopped with molten metal in it, the back-up rolls can be machined out of round or eccentricities can exist between the rolling center and the surface of the roll against which the belt rests. In these cases, the back-up roll can be replaced by a robotic arm or other suitable automated technique followed by adjustment of the replacement back-up roll, which commonly has dimensional adjustments at the bearings. The same can be true of a roll caster, with eccentricities, flat spots, and coating thickness variations. The roll can be replaced by a robotic arm or other suitable automated technique followed by adjustment of the replacement roll, which commonly has a point of adjustment or adjustment point at the bearing points. There are commonly sensors that are made up of a series of rings that measure tight spots in the cast strip, slab, or sheet. A roll can be made using actuators in place of sensors to make changes in the geometry of the mold of a roll caster. The roll can include a series of rings on the center shaft with adjustments from the shaft access to accommodate thickness variations across the face of the cast surface due to a variation in roll geometry or even metal temperature variations causing dimensional variation in the slab thickness.

The disclosure can apply to a wide variety of alloys, such as aluminum, aluminum alloys, magnesium, magnesium alloys, copper, copper alloys, and steel. Aluminum alloys, for example, include AA 1XXX, 2XXX, 3XXX, 4XXX, 5XXX, 6XXX, and 7XXX.

A 1000 series-based aluminum alloy typically has the following composition:

(i) from about 0.05 to about 0.20% by weight magnesium;

(ii) from about 0.01 to about 0.20% by weight manganese;

(iii) from about 0.01 to about 0.25% by weight copper;

(iv) from about 0.001 to about 0.08% by weight iron;

(v) from about 0.001 to about 0.02% by weight silicon;

(vi) from about 0.001 to about 0.095% by weight chromium;

(vii) from about 0.01 to about 0.45% by weight zinc;

(viii) from about 0.001 to about 0.045% by weight nickel;

(ix) from about 0.01 to about 0.175% by weight titanium; and

(x) no more than about 0.05 wt. % other impurities.

A 2000 series-based aluminum alloy typically has the following composition:

(i) from about 0.02 to about 1.8% by weight magnesium;

(ii) from about 0.1 to about 1.2% by weight manganese;

(iii) from about 1.8 to about 6.8% by weight copper;

(iv) from about 0.07 to about 1.0% by weight iron;

(v) from about 0.05 to about 0.5% by weight silicon;

(vi) from about 0.05 to about 0.8% by weight chromium;

(vii) from about 0.05 to about 1.4% by weight zinc;

(viii) from about 0.01 to about 0.2% by weight nickel;

(ix) from about 0.01 to about 0.175% by weight titanium; and

(x) no more than about 0.05 wt. % other impurities.

A 3000 series-based aluminum alloy typically has the following composition:

(i) from about 0.01 to about 1.3% by weight magnesium;

(ii) from about 0.01 to about 1.3% by weight manganese;

(iii) from about 0.01 to about 0.3% by weight copper;

(iv) from about 0.1 to about 0.7% by weight iron;

(v) from about 0.10 to about 1.7% by weight silicon;

(vi) from about 0.01 to about 0.35% by weight chromium;

(vii) from about 0.001 to about 0.09% by weight zinc;

(viii) from about 0.001 to about 0.09% by weight nickel;

(ix) from about 0.001 to about 0.09% by weight titanium; and

(x) no more than about 0.15 wt. % other impurities.

A 4000 series-based aluminum alloy typically has the following composition:

(i) from about 0.05 to about 2.0% by weight magnesium;

(ii) from about 0.05 to about 1.5% by weight manganese;

(iii) from about 0.05 to about 5.0% by weight copper;

(iv) from about 0.09 to about 1.0% by weight iron;

(v) from about 0.6 to about 13.5% by weight silicon;

(vi) from about 0.05 to about 0.25% by weight chromium;

(vii) from about 0.05 to about 1.3% by weight zinc;

(viii) from about 0 to about 2.2% by weight nickel;

(ix) from about 0.5 to about 0.3% by weight titanium; and

(x) no more than about 0.05 wt. % other impurities.

A 5000 series-based aluminum alloy useful for producing tab or end stock has the following composition:

(i) from about 2.0 to about 5.0% by weight magnesium;

(ii) from about 0.10 to about 1.25% by weight manganese;

(iii) from about 0.001 to about 0.45% by weight copper;

(iv) from about 0.1 to about 0.85% by weight iron;

(v) from about 0.1 to about 1.3% by weight silicon;

(vi) from about 0.01 to about 0.3% by weight chromium;

(vii) from about 0.75 to about 2.7% by weight zinc;

(viii) from about 0.001 to about 0.045% by weight nickel;

(ix) from about 0.01 to about 0.175% by weight titanium; and

(x) no more than about 0.15 wt. % other impurities.

A 6000 series-based aluminum alloy typically has the following composition:

(i) from about 0.2 to about 3.0% by weight magnesium;

(ii) from about 0.05 to about 1.0% by weight manganese;

(iii) from about 0.05 to about 0.9% by weight copper;

(iv) from about 0.1 to about 0.8% by weight iron;

(v) from about 0.3 to about 1.5% by weight silicon;

(vi) from about 0.03 to about 0.35% by weight chromium;

(vii) from about 0.05 to about 1.0% by weight zinc;

(viii) from about 0 to about 0.2% by weight nickel;

(ix) from about 0 to about 0.2% by weight titanium; and

(x) no more than about 0.05 wt. % other impurities.

A 7000 series-based aluminum alloy typically has the following composition:

(i) from about 0.1 to about 3.3% by weight magnesium;

(ii) from about 0.04 to about 0.8% by weight manganese;

(iii) from about 0.1 to about 2.8% by weight copper;

(iv) from about 0 to about 0.5% by weight iron;

(v) from about 0.05 to about 0.4% by weight silicon;

(vi) from about 0.04 to about 0.28% by weight chromium;

(vii) from about 0.8 to about 12% by weight zinc;

(viii) from about 0 to about 0.03% by weight nickel;

(ix) from about 0.03 to about 0.2% by weight titanium; and

(x) no more than about 0.05 wt. % other impurities.

More specifically, the cast strip can be comprise an aluminum alloy selected from the group of consisting of aluminum alloys 1050, 1060, 1100, 1199, 2014, 2024, 2219, 303, 3004, 3102, 4041, 5005, 5052, 5083, 5086, 5154, 5182, 5356, 5454, 5456, 5754, 6005, 6005A, 6014, 6022, 6060, 6061, 6063, 6066, 6070, 6082, 6105, 6111, 6016, 6162, 6262, 6351, 6463, 7005, 7022, 7050, 7068, 7072, 7075, 7079, 7116, 7129, and 7178. In some embodiments, the cast strip can be comprise an aluminum alloy suitable for aircraft or aerospace structures selected from the group of consisting of aluminum alloys 2024, 5052, 6061, 6063, 7050, 7068, and 7075. In some embodiments, the cast strip can be comprise an aluminum alloy suitable for marine structures selected from the group of consisting of aluminum alloys 5052, 5059, 5083, 5086, 6061, and 6063. In some embodiments, the cast strip can be comprise an aluminum alloy suitable for automotive structures selected from the group of consisting of aluminum alloys 2008, 2036, 5083, 5456, 5754, 6016, and 6111.

Examples of the processors as described herein may include, but are not limited to, at least one of Qualcomm® Snapdragon® 800 and 801, Qualcomm® Snapdragon® 610 and 615 with 4G LTE Integration and 64-bit computing, Apple® A7 processor with 64-bit architecture, Apple® M7 motion coprocessors, Samsung® Exynos® series, the Intel® Core™ family of processors, the Intel® Xeon® family of processors, the Intel® Atom™ family of processors, the Intel Itanium® family of processors, Intel® Core® i5-4670K and i7-4770K 22 nm Haswell, Intel® Core® i5-3570K 22 nm Ivy Bridge, the AMD® FX™ family of processors, AMD® FX-4300, FX-6300, and FX-8350 32 nm Vishera, AMD® Kaveri processors, Texas Instruments® Jacinto C6000™ automotive infotainment processors, Texas Instruments® OMAP™ automotive-grade mobile processors, ARM® Cortex™-M processors, ARM® Cortex-A and ARM926EJ-S™ processors, other industry-equivalent processors, and may perform computational functions using any known or future-developed standard, instruction set, libraries, and/or architecture.

The exemplary systems and methods of this disclosure have been described in relation to a block casting system. However, to avoid unnecessarily obscuring the present disclosure, the preceding description omits a number of known structures and devices. This omission is not to be construed as a limitation of the scopes of the claims. Specific details are set forth to provide an understanding of the present disclosure. It should however be appreciated that the present disclosure may be practiced in a variety of ways beyond the specific detail set forth herein.

Furthermore, while the exemplary aspects, embodiments, and/or configurations illustrated herein show the various components of the system collocated, certain components of the system can be located remotely, at distant portions of a distributed network, such as a LAN and/or the Internet, or within a dedicated system. Thus, it should be appreciated, that the components of the system can be combined in to one or more devices or collocated on a particular node of a distributed network, such as an analog and/or digital telecommunications network, a packet-switch network, or a circuit-switched network. It will be appreciated from the preceding description, and for reasons of computational efficiency, that the components of the system can be arranged at any location within a distributed network of components without affecting the operation of the system. Similarly, one or more functional portions of the system could be distributed between multiple device(s).

Furthermore, it should be appreciated that the various links connecting the elements can be wired or wireless links, or any combination thereof, or any other known or later developed element(s) that is capable of supplying and/or communicating data to and from the connected elements. These wired or wireless links can also be secure links and may be capable of communicating encrypted information. Transmission media used as links, for example, can be any suitable carrier for electrical signals, including coaxial cables, copper wire and fiber optics, and may take the form of acoustic or light waves, such as those generated during radio-wave and infra-red data communications.

Also, while the flowcharts have been discussed and illustrated in relation to a particular sequence of events, it should be appreciated that changes, additions, and omissions to this sequence can occur without materially affecting the operation of the disclosed embodiments, configuration, and aspects.

A number of variations and modifications of the disclosure can be used. It would be possible to provide for some features of the disclosure without providing others.

For example in one alternative embodiment, the control system is embodied as an artificially intelligent algorithm able to modify its behavior based on repeated observations, such as using fuzzy logic, expert systems, neural networks, and robotics. Artificial intelligence can observe the effects of casting component wear on casting performance and cast strip surface properties/defects and adjusting adjustment points over time and modify when the component is replaced and to what degree and how adjustments are made to adapt to changes in behavior of the casting system. For example, blocks wear, thermal conditions change, alloy compositions change, and the like.

In yet another embodiment, the systems and methods of this disclosure can be implemented in conjunction with a special purpose computer, a programmed microprocessor or microcontroller and peripheral integrated circuit element(s), an ASIC or other integrated circuit, a digital signal processor, a hard-wired electronic or logic circuit such as discrete element circuit, a programmable logic device or gate array such as PLD, PLA, FPGA, PAL, special purpose computer, any comparable means, or the like. In general, any device(s) or means capable of implementing the methodology illustrated herein can be used to implement the various aspects of this disclosure. Exemplary hardware that can be used for the disclosed embodiments, configurations and aspects includes computers, handheld devices, telephones (e.g., cellular, Internet enabled, digital, analog, hybrids, and others), and other hardware known in the art. Some of these devices include processors (e.g., a single or multiple microprocessors), memory, nonvolatile storage, input devices, and output devices. Furthermore, alternative software implementations including, but not limited to, distributed processing or component/object distributed processing, parallel processing, or virtual machine processing can also be constructed to implement the methods described herein.

In yet another embodiment, the disclosed methods may be readily implemented in conjunction with software using object or object-oriented software development environments that provide portable source code that can be used on a variety of computer or workstation platforms. Alternatively, the disclosed system may be implemented partially or fully in hardware using standard logic circuits or VLSI design. Whether software or hardware is used to implement the systems in accordance with this disclosure is dependent on the speed and/or efficiency requirements of the system, the particular function, and the particular software or hardware systems or microprocessor or microcomputer systems being utilized.

In yet another embodiment, the disclosed methods may be partially implemented in software that can be stored on a storage medium, executed on programmed general-purpose computer with the cooperation of a controller and memory, a special purpose computer, a microprocessor, or the like. In these instances, the systems and methods of this disclosure can be implemented as program embedded on personal computer such as an applet, JAVA® or CGI script, as a resource residing on a server or computer workstation, as a routine embedded in a dedicated measurement system, system component, or the like. The system can also be implemented by physically incorporating the system and/or method into a software and/or hardware system.

Although the present disclosure describes components and functions implemented in the aspects, embodiments, and/or configurations with reference to particular standards and protocols, the aspects, embodiments, and/or configurations are not limited to such standards and protocols. Other similar standards and protocols not mentioned herein are in existence and are considered to be included in the present disclosure. Moreover, the standards and protocols mentioned herein and other similar standards and protocols not mentioned herein are periodically superseded by faster or more effective equivalents having essentially the same functions. Such replacement standards and protocols having the same functions are considered equivalents included in the present disclosure.

The present disclosure, in various aspects, embodiments, and/or configurations, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various aspects, embodiments, configurations embodiments, sub combinations, and/or subsets thereof. Those of skill in the art will understand how to make and use the disclosed aspects, embodiments, and/or configurations after understanding the present disclosure. The present disclosure, in various aspects, embodiments, and/or configurations, includes providing devices and processes in the absence of items not depicted and/or described herein or in various aspects, embodiments, and/or configurations hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and\or reducing cost of implementation.

The foregoing discussion has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the disclosure are grouped together in one or more aspects, embodiments, and/or configurations for the purpose of streamlining the disclosure. The features of the aspects, embodiments, and/or configurations of the disclosure may be combined in alternate aspects, embodiments, and/or configurations other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claims require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed aspect, embodiment, and/or configuration. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the disclosure.

Moreover, though the description has included description of one or more aspects, embodiments, and/or configurations and certain variations and modifications, other variations, combinations, and modifications are within the scope of the disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative aspects, embodiments, and/or configurations to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.

Claims

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.