Abstract: A method (300) and a system (100) for controlling a casting process are described herein. The system (100) generally includes a die casting device (110) and a measuring device (120). The die casting device (110) includes a mold (130) configured to produce molded parts (140). The measuring device (120) may determine a position of the mold (130) within the die casting device (110) in a casting cycle. The measuring device (120) may determine an incremental increase in weight of molded parts (140) associated with the casting cycle. Based on the incremental increase in weight of molded parts (140), the measuring device (120) may provide a notification in response to a trigger event. The measuring device (120) may also reset the die casting device (110) for another casting cycle based on the incremental increase in weight of molded parts (140).

Abstract: A method of finishing like castings wherein the exact dimensions of the casting are not known requires the steps of traversing the casting along a fixed path impinging excess material on a reduction apparatus such as grinder at a fixed location such that a defined witness is produced on the excess material, measuring the difference from the witness to the casting parent material and adjusting the fixed path to remove the excess material to within a specified tolerance.

Abstract: A method for detecting roller irregularities during on-line continuous casting of a metal comprises; i) continuously monitoring the changes in the mould level over time; ii) identifying large periodic influences affecting the mould level versus time function and their frequency, iii) comparing the frequency of the periodic influences of step ii) with predicted frequency harmonics based on a normal operation of the casting process and highlighting by comparison of the predicted and actual frequencies characteristics indicative of irregularities in roller behavior.

Abstract: Device and method to control the straightness and torsions of a long product (11), comprising at least two profile-detection devices (12a, 12b, 12c), each presenting a visual field (13) that includes a perimeter segment (18a, 18b, 18c) of the section of the product (11). The detection devices are aligned along the product (11) and are oriented so as to detect homologous perimeter segments (18a, 18b, 18c) located on different planes. The device also comprises a command unit which receives and compares with each other the section images detected at the same instant by the detection devices (12a, 12b, 12c) and determines, according to this comparison, the lack of straightness and/or the presence of torsions in the product (11).

Abstract: A new start-up operation of a continuous caster is monitored by comparing itself with the normal start-up operation, which is benchmarked by a multivariate statistical model using selected historical operation data. If the new operation is statistically different from the benchmark, then alarms are generated to indicate an impending start cast breakout and at the same time, the process variables that lead to process excursions from the normal operation are identified as the most likely root causes of the predicted breakout. The model is built using Mult-way Principal Component Analysis technology to characterize the operation-to-operation variance in a reduced dimensional space (also known as latent variable space) based on a large number of process trajectories from past normal start-up operations. The process trajectories over the entire start cast duration are predicted based on the current observations.

Abstract: A method and a device for operating an installation of a primary industry, particularly a continuous casting and rolling installation, using a computer system. Products assigned to different production orders are produced in the installation, and a production plan is generated using method steps for order selection, pre-planning, planning and optimization.

Abstract: An apparatus and method for creating expanded and non-expanded regions on a sheet of sheet metal. The apparatus includes a programmable controller, a sheet metal feeder for incrementally advancing the sheet metal, and a cutter/expander for generating rows of expanded metal apertures. The controller selectively controls both the amount of incremental advance provided to the sheet metal by the feeder and the timing and location of the cutting and expanding provided by the cutter/expander; the combination of which creates such regions.

Abstract: A method for detecting roller irregularities during on-line continuous casting of a metal comprises; i) continuously monitoring the changes in the mould level overtime; ii) identifying large periodic influences affecting the mould level versus time function and their frequency, iii) comparing the frequency of the periodic influences of step ii) with predicted frequency harmonics based on a normal operation of the casting process and highlighting by comparison of the predicted and actual frequencies characteristics indicative of irregularities in roller behaviour.

Abstract: A method of monitoring the operation of a continuous caster in which a multivariate statistical model is developed using off-line measurements of process parameters representing normal operation of the continuous caster. On-line process parameters are measured in real time to determine if the caster operation is normal by calculating test statistics on vectors calculated using the multivariate statistical model with input from the on-line process parameters. The method may advantageously be used to predict breakouts in a continuous caster and allows an operator to take corrective action to avoid such breakouts. Corrective action may also be taken automatically.

Abstract: An alarm system for a casting mold is provided, which includes an alarm electrically connected to the casting mold; and at least one sensing unit electrically connected to the alarm, and spaced apart by a predetermined gap from a cast to be drawn from the casting mold. During a drawing process, if the cast is formed with failure in appearance such as deformation, burr edges or uneven thickness, the cast drawn out of the casting mold would come into contact with the sensing unit and thereby induce the alarm to generate an alarm signal to notify an operator who may immediately solve any operational problems.

Abstract: A continuous caster is controlled by a method anticipating the liquidus temperature in the mold of the caster to prevent premature solidification. The temperature in the tundish is measured and based upon the tundish temperature and the resistance time of the molten metal in the tundish, an equivalent liquidus temperature window is defined and the speed of the continuous caster is controlled to maintain this window of operation of the tundish.

Abstract: A method and apparatus is disclosed to improve the metal yield by adjusting the tilt angle of a tilting vessel having a submerged tap hole. The tilt angle is adjusted in response to parameters inherent in the pouring process, i.e. the proximity of the vessel contents to the vessel lip, the age of the tap hole, the liquid head over the tap hole, etc. Additionally, methods are disclosed to enhance the metal yield by advancing or moving back the furnace without knowledge of the tilt angle. Moreover, such methods and apparatus can be implemented through the use of computer based algorithms. The methods can also be used to archive pouring parameter information for future uses such as training and reviewing.

Abstract: A predictive industrial control system for controlling individual cells of machines through multiple Programmable Logic Controllers in an investment casting processing and handling operation. An application server located in a remote, non-industrial environment executes an industrial control application (ICA) utilizing tagged reference names corresponding to individual machines and information input devices such as sensors on the production line. The ICA accesses local databases that hold casting shell part numbers and their associated recipe control words, and monitors the system for new shell part numbers as they appear on a load conveyor in the production line. Radio Frequency tags on the part signal the ICA to transfer the appropriate recipe control words and robot moves required to process the part in a primary processing cell's PLC. The PLC then controls each machine in the primary processing cell in accordance with the downloaded commands from the ICA.

Abstract: A method (100) for predicting distortion of a sheet metal during a sheet forming process to form the sheet metal into a part. The method (100) of the present invention is for use with a computer including memory and sheet forming tools. The method (100) comprises applying (104-116) the radial return method to compute the total stress for the anisotropic hardening rule of Mroz. The method (100) of the present invention does not divide a given strain increment into hundreds of subintervals as long as the movement of the center of the active yield surface is along a fixed path. If a break occurs, the given strain increment is divided into a few segments (110).

Abstract: In an apparatus for minimizing vacuum losses from a permeable support surface having one or more layers of sheet-type work material positioned thereon, the support surface includes opposed lateral edge surfaces, each defining an upper and lower section. At least two upper seals are coupled to the frame, each engaging the upper section of one of the lateral edge surfaces and extending approximately the length of the support surface. At least two side seals are also provided and are coupled to the frame, each engaging the side section of one of the lateral edge surfaces and also extending approximately the length of the support surface. During operation of the apparatus, vacuum is drawn through the permeable support surface and causes the upper and side seals to be drawn and held against the lateral side sections, forming a seal there against.

Abstract: A process and a device for comprehensive control of a basic industry plant, such as a steel plant or an integrated iron works, which includes subprocesses that are critical with regard to continuous material flow, e.g., casting processes. The invention optimizes the material flow through the system and prevents the interruption of the material flow prior to the start of subprocesses that are critical with regard to continuous material flow. The process sequence in a subprocess is subdivided into four steps, referred to as quarter cells with each quarter cell containing a point in time, a time range to describe possible process time fluctuations, the name of the previous quarter cell, i.e., the name of the previous substep of a subprocess, as well as a marker of whether the process time fluctuation of this subcell is influenceable or non-influenceable.

Abstract: A numerical controller controls a machine tool to achieve a tapping operation with high accuracy and satisfactory quality without being constrained by a set axial feed distance and a specified axial feed speed. An analyzing unit (4B) calculates a minimum axial feed distance (L.sub.min) necessary for securing a constant machining program set in an input unit (7). A speed pattern adjusting unit (4C) modifies the axial feed speed pattern so that the constant speed time (T) can be secured. An(??) distributing unit (4A) determines drive instructions for a synchronous tapping operation. A drive control unit (5) gives the drive instructions to servomotors included in a driving unit (3).