Abstract: A twin roll casting system includes a pair of counter-rotating casting rolls, a casting roll controller is configured to receive a plant input comprising at least one process control setpoint for the casting rolls. A cast strip sensor measures at least one parameter of the cast strip. A feedback controller receives measurement signals from the cast strip sensor. The feedback controller is a data-driven model including a database of state-input pairs; and executes the following steps at each time step: measure a state-input similarity between a new state observation and samples, assign a weight to each consequent output of samples based on the measured state input similarity, and sum the weighted outputs and predict an output of a new state observation. The feedback controller is configured to provide the control setpoint to the casting roll controller based on the predicted output of the new state observation.

Abstract: A device and method are disclosed for positioning at least one of two casting rolls in a continuous casting process for producing a metal strip. The device and the method allow adjusting or modifying the casting gap between the casting rolls during the ongoing operation, thereby having an influence on the strip thickness and the strip profile of the produced metal strip.

Abstract: In a vacuum-die casting machine comprising a casting mold having stationary and movable mold halves defining therebetween a mold cavity, a casting chamber which is in communication with the mold cavity and includes a piston and an evacuation arrangement connectable to the casting chamber for drawing melt from a melt storage into the casting chamber, a control arrangement is provided for controlling the mold cavity pressure depending on the pressure difference between the mold cavity and a cavity pressure and a counter pressure of the metal melt.

Abstract: A quality management device and a die-cast molding machine capable of suitably inspecting quality in relation to the amount of blowholes of a die-cast product which is cast according to a PF die casting method are provided. A quality management device 3 performs the quality management of the die-cast product formed according to the pore free die casting method of supplying oxygen to a cavity Ca and an injection sleeve 27 communicated with the cavity Ca and, in that state, ejecting a melt in the injection sleeve 27 into the cavity Ca. Further, the quality management device 3 has a vacuum sensor 51 which detects the air pressure in the cavity Ca and a control device 70 which makes good/defective judgment of quality of the die-cast product in relation to the amount of blowholes based on the air pressure detected by the vacuum sensor 51 during injection.

Abstract: A device and method are disclosed for positioning at least one of two casting rolls in a continuous casting process for producing a metal strip. The device and the method allow adjusting or modifying the casting gap between the casting rolls during the ongoing operation, thereby having an influence on the strip thickness and the strip profile of the produced metal strip.

Abstract: A continuous casting installation (20) including a strand guide having strand casting segments with rollers (2) for guiding a cast strand, wherein at least one of the strand casting segments (22, 23, 24, 25, 26, 27) is formed as a measurement segment, wherein there is provided at least one measurement point for direct or indirect determination of a force acting on one or several rollers (2), wherein further the at least one measurement point is provided on a support housing (30), preferably between the support and the segment frame of strand casting segment, and there is provided a data processing unit that based on data of the at least one measurement point determines the solidification states of the cast strand.

Abstract: Disclosed is a molding machine for simultaneously making upper and lower molds with cope and drag flasks, a matchplate, upper and lower squeezing boards, and a lower filling frame. This machine also includes a cylinder for raising and lowering the lower squeezing board, a driving mechanism that includes pneumatic and hydraulic piping systems for driving the cylinder using an air-on-oil system, and a controller for controlling the driving mechanism. The drag flask, the matchplate, the filling frame, and the lower board define a lower molding space, while the matchplate, the upper board, and the cope flask define an upper molding space such that the controller controls the driving mechanism to drive the cylinder at a low pressure. The lower squeezing board is raised to squeeze the molding sand for simultaneously making the two molds such that the controller controls the driving mechanism to drive the cylinder at a high pressure.

Abstract: A steel slab caster having a mold with movable opposing mold faces, and methods of using the steel slab caster for casting steel slabs. The movable opposing mold faces may be laterally positioned with respect to each other in a predefined configuration. Molten steel may be introduced into the mold of the slab caster. The forces exerted by the molten metal on at least one of the opposing mold faces and/or the lateral positions of the opposing mold faces may be monitored during casting at locations on at least one of the movable mold faces. The position of the monitored mold face may be controlled during casting responsive to the monitored forces and/or monitored position.

Abstract: A control method for supplying an inert gas from an inert gas source to a storage container for a molten metal through a gas feed path provided with a flow sensor for monitoring the gas flow rate and a solenoid valve for opening and closing the gas feed path for use with metal molding. The control method includes steps of turning off the solenoid valve if a temperature of the storage container is lower than a preset temperature, and turning off the flow sensor; otherwise turning on the solenoid valve and turning on the flow sensor; and stopping the output of the heater of the storage container when the gas flow rate is lower than the preset amount; these steps are controlled in accordance with a command signal from a controller.

Abstract: A dual temperature mold assembly for maintaining a mold cavity used in a cast on strap process at two different temperatures facilitates the removal of the solidified strap after the molten metal is solidified. The mold assembly includes a mold cavity having walls attached to different mold assembly segments that are heated or cooled by thermal energy input and coolant processes which can maintain the mold cavities at different temperatures, so that molten metal around the battery plate lugs in a mold cavity segment is solidified while the sides of the mold cavity are exposed to at least one adjacent heated segment to provide thermal energy thereinto, resulting in a reduction of the amount of molten metal necessary for a cast on strap, and reducing the amount of thermal energy input into the process for manufacturing the straps.

Abstract: The method of producing thin cast strip by continuous casting is disclosed. At least two sensors are operationally connected to at least one end of at least one of a pair of casting rolls or of a pair of brushes, to continuously measure at least two force-related parameters during casting. At least two time domain signals corresponding to the measured force-related parameters are generated. The time domain signals are continuously monitored and transformed into corresponding frequency domain spectrums. The frequency domain spectrums are analyzed and composite intensity values are continuously calculated from the intensity levels of at least a portion of the frequency component signals within the frequency spectrums. Casting parameters are adjusted in response to reduce strip defects.

Abstract: A hydraulic power unit 15 of a match-plate molding machine comprises a hydraulic pump 20 for supplying oil, a piping system 21, 25, and 26 that fluidly communicates with first and second hydraulic cylinder systems 7 and 10 for supplying the oil from the hydraulic pump 20 to them to perform a squeeze step, an accumulator 22 that is provided within the piping system, first and second electromagnetic directional control valves 23 and 24 for controlling the flow of the oil from the hydraulic pump 20 to the first and second hydraulic cylinder systems 7 and 10, first and second pressure sensors 27 and 28 for measuring pressures of the oil of the first and second hydraulic cylinder systems 7 and 10, and for generating output signals that correspond to the measured value, and a controller 29 for receiving the output signals from the first and second pressure sensors 23 and 24, and for controlling the turns of the first and second electromagnetic directional control valves 23 and 24 based on the output signals and the

Abstract: A method of controlling the operation of an apparatus for making an upper and a lower mold and the apparatus therefore that prevents a mold from having a wrap or a match plate from being damaged. The apparatus controls the forward movement of an upper and a lower squeeze member such that when each moves forward to the match plate by a squeeze device, the difference in the squeeze forces imparted to the upper squeeze member and the squeeze force imparted to the lower squeeze member, is kept within the predetermined tolerance.

Abstract: A tundish carriage with a lifting device (1) for a tundish (2) for liquid steel materials, in particular in a multi-strand caster, wherein the tundish (2) is supported, with a possibility to be lifted or lowered, by controlled electromechanical or hydraulic lifting devices (1a, 1b) on a carriage frame (7), prevents a quadruple arrangement of piston-cylinder units and a complicated synchronization control, with security for personnel and a noticeable simplification of construction, by providing a single vertical support (9) and only two lifting devices (1a, 1b).

Abstract: A die casting method initially injects an alloy with minimal volumetric contraction during solidification into a die cavity, monitors at least one of the pressure of the shot cylinder and the position of the plunger, and reduces the injection pressure during the final stage of filling of the die mold. A die casting machine includes a shot cylinder having one of a pressure detector located for detecting the hydraulic pressure applied to the cylinder or a position sensor for a plunger rod. The plunger rod includes a tip extending into a cold chamber, which receives a metal alloy having a minimal shrinkage characteristic. A source of hydraulic pressure is coupled to the shot cylinder by a control valve and a control circuit is coupled to said valve and to one of said detector or sensor for reducing the injection pressure near the end of an injection cycle.

Abstract: A method of operation for an apparatus for making an upper and a lower mold and the apparatus therefore that can prevent a mold from having a wrap or a match plate from being damaged. The apparatus for making an upper and a lower mold of the present invention controls the forward movement of an upper and a lower squeeze member such that when they each move forward to the match plate by means of the squeeze means of the upper and lower molds the difference in the squeeze forces imparted by the upper squeeze means to the upper squeeze member, and the squeeze force imparted by the lower squeeze means to the lower squeeze member, is kept within the predetermined tolerance.

Abstract: A molding machine able to stably detect an abnormality of a squeeze pin, for example, a die cast machine having a squeeze pin able to apply pressure to a melt of a cavity repeatedly performing a molding cycle including a pressing process making the squeeze pin advance and applying pressure to the melt of the cavity in a state where the melt is filled in the cavity and a spray process making the squeeze pin advance and performing at least one of lubrication and cooling of the squeeze pin in the state where the melt is not filled in the cavity, and, in the spray process, detecting a stroke of the squeeze pin and detecting an abnormality of the squeeze pin based on a comparison of the detection result about the stroke and a predetermined reference value.

Abstract: A clamping force sensor system includes a clamping force sensor device, a signal-converting program carrier, and an output device. The clamping force sensor device includes a body mounted to a tie bar of a forming machine. The clamping force sensor device further includes a sensor mounted to the body, with a portion of the sensor exposed outside of the body. The signal-converting program carrier is electrically connected to the sensor by at least one signal line. The signal-converting program carrier includes a built-in program for converting a signal from the at least one signal line into a mold-clamping force. The output device is electrically connected to the signal-converting program carrier for outputting the mold-clamping force.

Abstract: To provide a mold clamping apparatus able to suppress spout of a molding material from between mating faces of dies and to extend the lifetime of the dies. A mold clamping apparatus has a control apparatus deciding a distribution of a load divided by a plurality of tie bars based on information concerning to the die and controlling pressure of driving oil of a cylinder chamber of each cylinder for mold clamping independently to become a load having a determined distribution.

Abstract: A monitor system for monitoring a molding machine that includes a vertically-movable supporting frame, a pattern carrier on which a pattern is placed, a flask placed on a leveling frame, a sand hopper provided with an optional an air-jet chamber, sand-charging nozzles disposed around a plurality of squeeze feet that is disposed at a lower end of the sand hopper, and a filling frame connected to filling-frame cylinders and surrounding the squeeze feet and the sand-charging nozzles from their outside, the filling frame to be placed on the flask when lowered, comprising at least one sensor connected to the molding machine, for detecting an attribute of the molding sand as required and data analyzing monitor means connected to the sensor, for receiving data that correspond to the attribute detected by the sensor and analyzing the attribute and displaying the results of the analysis.

Abstract: A method and apparatus are disclosed for controlling temperature of a plant comprising plural temperature control zones, wherein an effective control parameter for a first zone for which a signal representing measured temperature is available is produced according to an algorithm relating measured temperature, a desired temperature and a control parameter associated with a device affecting temperature in the first temperature control zone, the effective control parameter is summed with an offset value representing a proportional offset of the effective control parameter of a second temperature control zone relative to the effective control parameter of the first temperature control zone and the result is applied to control a device affecting temperature in the second temperature control zone.

Abstract: A monitor system for monitoring a molding machine that includes a vertically-movable supporting frame, a pattern carrier on which a pattern is placed, a flask placed on a leveling frame, a sand hopper provided with an optional an air-jet chamber, sand-charging nozzles disposed around a plurality of squeeze feet that is disposed at a lower end of the sand hopper, and a filling frame connected to filling-frame cylinders and surrounding the squeeze feet and the sand-charging nozzles from their outside, the filling frame to be placed on the flask when lowered, comprising at least one sensor connected to the molding machine, for detecting an attribute of the molding sand as required and data analyzing monitor means connected to the sensor, for receiving data that correspond to the attribute detected by the sensor and analyzing the attribute and displaying the results of the analysis.

Abstract: To provide a monitoring system for remotely monitoring the operation of a molding apparatus or an air-flow and press molding apparatus. The monitoring systems for monitoring a molding apparatus and an airflow and press molding apparatus include sensors, a local unit, and a remote unit. The local unit transmits the signals associated with the required attributes, which are measured by the sensors, of the molding apparatus to the remote unit via the communication network. The remote unit is designed so that it receives the signals transmitted from the local unit; thereby the user can monitor the molding apparatus or the air-flow and press molding apparatus remotely at the production and operation by them.

Abstract: The invention relates to a method and a device for the continuous casting of slabs or ingots, in particular of thin slabs in a continuous casting installation. Said installation comprises a soft reduction section in a continuous casting guide under the mould. The soft reduction section contains pressure rollers and support roller (3, 4), which are continuously restrained in relation to one another, either individually or as a segment (1), by means of hydraulic cylinders (7, 7?) and are restrained in a limiting manner by stops (30). The installation uses a hard-pressure restraining force in an area of the soft reduction section that has not yet completely solidified and a soft-pressure restraining force in an area of the soft reduction section that has completely solidified.

Abstract: The invention relates to a method and a device for the continuous casting of slabs or ingots, in particular of thin slabs in a continuous casting installation. Said installation comprises a soft reduction section in a continuous casting guide under the mould. The soft reduction section contains pressure rollers and support roller (3, 4), which are continuously restrained in relation to one another, either individually or as a segment (1), by means of hydraulic cylinders (7, 7′) and are restrained in a limiting manner by stops (30). The installation uses a hard-pressure restraining force in an area of the soft reduction section that has not yet completely solidified and a soft-pressure restraining force in an area of the soft reduction section that has completely solidified.

Abstract: To provide a monitoring system for remotely monitoring the operation of a molding apparatus or an air-flow and press molding apparatus. The monitoring systems for monitoring a molding apparatus and an air-flow and press molding apparatus include sensors, a local unit, and a remote unit. The local unit transmits the signals associated with the required attributes, which are measured by the sensors, of the molding apparatus to the remote unit via the communication network. The remote unit is designed so that it receives the signals transmitted from the local unit; thereby the user can monitor the molding apparatus or the air-flow and press molding apparatus remotely at the production and operation by them.

Abstract: A device for molding objects includes a mold having a molding space enclosed therein and adapted to be filled by a fluid mold material intended to solidify therein. The fluid mold material is injected under pressure into the molding space and solidifies under this high pressure. A chamber receives the mold and is filled with a medium. The medium filling the chamber and surrounding the mold is pressurized. The pressurized medium acts upon the mold from all directions with at least the same pressure magnitude as the pressure of the mold material within the mold. Therefore, the mold is isostatically balanced by the forces acting upon the mold by the mold material and the medium.

Abstract: In a process and in a device (10) for preparing the mold walls (12a, 12b) of a mold (12, 12) for the molding or shaping of a molded part after completion of the molding cycle and after removal of the molded part from the mold (12) to make the mold walls ready for the next molding cycle, the tempering of the mold walls (12a, 12b) and the coating of the walls with mold wall treatment agent are carried out independently of each other, i.e., without any time overlap, and in a controlled manner, preferably in a program-controlled manner. To apply the coating, preferably a spray element with centrifugal atomization and air control is used, the mold walls preferably being coated with essentially solvent-free mold wall treatment agent.

Abstract: A method of fabricating a porous metal structure of a molten liquid metal within a casting chamber to form a porous solid structure upon controlled chamber cooling and depressurization. The method includes provision of a pressurizable stationary mold casting chamber having a gas pressure release valve, a gas pressure measurement sensor, and a plurality of sites with respective surface-temperature or heat flux sensors and respective independently operable temperature controllers for regulating each respective site temperature. A data base driven microprocessor receives pressure and temperature data and selectively and independently adjusts pressure and temperature in accord with algorithmic commands relative required pressure reduction for pore formation and cooling for solidification to chosen extents of porosity and of solidification over a time period terminating upon porous solid-structure fabrication.

Abstract: A process for casting a continuous metal strand, in particular steel, in a continuous casting apparatus having strand parts disposed opposite one another and being fitted with bearings in which guide rollers are mounted, and having actuators by which a gap between respective opposed rollers can be set infinitely variable, and which method includes sensing a value representing a compressive force which occurs in the bearings and feeding said value to a computing unit; comparing the individual measured force values of a roller or of a pair of oppositely disposed rollers with respect to a level of the force; and utilizing at least the relating highest value measured as a command variable for controlling the gap and/or the casting rate and/or the amount of cooling water and/or the melt feed and/or the casting powder feed and/or the mold oscillation.

Abstract: An edge dam position control method and device in a twin roll strip casting process calculates the reduction ratio and rolling force of rolls to obtain the height of a solidification point, and adjusting the height of an edge dam during casting to correspond to the obtained height of the solidification point. It minimizes the force applied to the edge dam during casting, reduces the degree of wear of the edge dam, and improves the quality of edge portions of both sides of the strip.

Abstract: Spraycasting method involves directing an atomized metal or alloy spray at a collector disposed in a spray chamber and controlling temperature of the spray in flight in the spray chamber and of the atomized metal or alloy as it is deposited on the collector by a spray chamber pressure control technique that involves in-situ evacuation of the spray chamber during spray deposition to a maintain spray chamber gas partial pressure less than about 400 torr. Such low spray chamber gas partial pressure provides a higher temperature of the atomized spray in flight in the spray chamber and of the sprayed material as it is deposited on a collector in the spray chamber effective to reduce deposit porosity, reduce grain layering or banding, and provide a uniform grain through the thickness of the deposit.

Abstract: A caster including a device for delivering a gas into a space created by the apparatus that define the mold of the caster and the nozzle of the caster. Introducing a gas into the space resists backflowing and freezing of the molten metal to the nozzle. An associated method is also disclosed.

Abstract: An apparatus and method for pressure casting a battery part wherein the state of molten lead is monitored so that when the molten lead enters a liquid-to-solid transformation stage, the volume of the mold available for the lead to solidify therein is quickly reduced through a volume contraction step to thereby cause the molten lead to flow into the remaining volume at the same time one maintains pressure on the molten lead. As the molten lead solidifies under the reduced volume and high pressure it produces a battery part that is substantially free of both tears and cracks. In an alternate method, the lead is allowed to solidify and at least a portion of the lead is mechanically deformed through a volume contraction step to cause cracks or tears in the battery part to be eliminated thereby providing a battery part free of cracks or tears.