KR20240166544A - Automatic dam positioning system and method for controlling molten metal distribution to a continuous casting machine - Google Patents

Abstract

As a metal supply system, the metal supply system comprises an injector for dispensing molten metal into a movable mold, a supply vessel positioned upstream of the injector and defining a receiving area for receiving the molten metal, and a dam system. The dam system comprises a dam positionable within the receiving area and a controller capable of vertically positioning the at least one dam to control the flow of molten metal from the receiving area to the injector. As a method of controlling the distribution of molten metal into a continuous casting device, the method comprises the step of at least partially blocking the flow of molten metal from the receiving area to the injector using at least one dam in the receiving area. The method may comprise the step of detecting a temperature of the molten metal downstream of the at least one dam and controlling the vertical position of the at least one dam based on the detected temperature.

Description

Automatic dam positioning system and method for controlling molten metal distribution to a continuous casting machine

Cross-reference to related applications

This application claims priority to U.S. Provisional Application No. 63/362,135, filed March 30, 2022, entitled AUTOMATIC DAM POSITIONING SYSTEM AND METHOD FOR CONTROLLED MOLTEN METAL DISTRIBUTION FOR A CONTINUOUS CASTING MACHINE, the entire contents of which are incorporated herein by reference.

field

The present application relates to continuous casting of molten metals, and more particularly, to systems and methods for controlling the flow of molten metal into a movable mold for casting, including but not limited to a block, belt, and/or roll.

Metal products (e.g., metal strips, slabs and plates), particularly those made of aluminum and aluminum alloys, can be manufactured using continuous casting systems in which molten metal is fed into a gap formed by a movable mould. The metal product is continuously discharged from a casting cavity by the movable mould and can be produced in infinite lengths. Various types of movable moulds can be used, depending on the type of continuous casting system. For example, one type of continuous casting system is a twin-belt caster in which two opposing belts circulate continuously and the molten metal is fed by a launder or injector into a thin casting cavity formed between the opposing sections of the belts. Alternatively, there is a rotating block caster in which the casting surfaces are formed by blocks that rotate about a fixed path and are joined together adjacent the casting cavity to form a continuous surface. Another type of continuous casting system is the twin roll caster, which uses an injection device to feed molten metal into a gap formed between two rolls, casting the metal. As the metal comes into contact with the rolls, heat is rapidly extracted and the metal begins to solidify. The solidified metal is then compressed as it passes through the gap between the rolls.

In some continuous casting systems, such as twin roll casters, the exit cross-sectional profile of the cast metal product is directly related to the temperature profile of the molten metal at the tip of the injector that introduces the molten metal into the gap of the movable mold. However, control of this temperature profile has traditionally been limited and has required operators to implement the controls manually in close proximity to the molten metal, which increases the possibility of occupational accidents. Furthermore, traditional controls are inaccurate, non-troubleshootable, and erratic, resulting in cast metal products having undesirable geometries and/or requiring correction prior to further processing, which reduces productivity.

The embodiments included in this patent are defined by the claims below, not by the solution to the problem. The solution to the problem is a high-level overview of various embodiments, and introduces some of the concepts further described in the detailed description below. The solution to the problem is not intended to identify key or essential features of the claimed subject matter, and is not intended to be used alone to determine the scope of the claimed subject matter. The inventive subject matter should be understood by reference to pertinent portions of the entire specification of this patent, any and all of the drawings, and each claim.

According to certain embodiments, a metal supply system includes an injector for dispensing molten metal into a movable mold, a supply vessel positioned upstream of the injector and defining a receiving area for receiving the molten metal, and a dam system. The dam system includes at least one dam positionable within the receiving area and a controller operably coupled to the at least one dam for controlling a vertical position of the at least one dam within the receiving area to control a flow of molten metal from the receiving area to the injector.

According to some embodiments, a dam system for a metal supply system comprises a plurality of dams and a controller operably coupled to each dam of the plurality of dams. The controller is capable of controlling a vertical position of each dam of the plurality of dams independently of the other dams of the plurality of dams.

According to certain embodiments, a method of controlling distribution of molten metal into a continuous casting device comprises the steps of at least partially blocking the flow of molten metal from a receiving region to an injector using at least one dam in the receiving region, detecting a temperature of the molten metal downstream of the at least one dam, and controlling the vertical position of the at least one dam based on the detected temperature.

The various implementations described herein may include additional systems, methods, features, and advantages, which may not necessarily be explicitly set forth herein, but will become apparent to those skilled in the art upon review of the following detailed description and the accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within this disclosure and protected by the appended claims.

This specification makes reference to the accompanying drawings, wherein the use of like reference numerals in different drawings is intended to illustrate like or analogous components.
FIG. 1 is a side view of a twin roll casting system having a metal supply system according to embodiments.
Figure 2 is a plan view of a portion of the metal supply system of Figure 1.
Figure 3 illustrates a portion of a dam system of the metal supply system of Figure 1.
FIG. 4 illustrates a portion of a twin roll casting system having a metal supply system according to embodiments.
Figure 5 illustrates a portion of the dam system of the metal supply system of Figure 4.
Figure 6 illustrates a portion of the dam system of the metal supply system of Figure 4.
Figure 7 illustrates an actuator of the dam system of the metal supply system of Figure 4.

Systems and methods for controlling the distribution of molten metal to a continuous casting device, including but not limited to a twin roll caster, are described herein. The systems and methods described herein may be used with any metal, but they may be particularly useful with aluminum or aluminum alloys. In certain embodiments, a metal supply system for supplying molten metal to a continuous casting device includes a dam system having at least one movable dam and a controller. In various embodiments, the dam system includes a plurality of movable dams, such as but not limited to two movable dams, three movable dams, four movable dams, five movable dams, six movable dams, seven movable dams, eight movable dams, nine movable dams, and the like. In some embodiments, although not required in other embodiments, the dam system includes an odd number of movable dams.

A controller is operatively coupled to at least one dam to control the vertical position of the at least one dam within the flow path of the molten metal (e.g., within the receiving area of a feed vessel or tundish) thereby controlling distribution of the molten metal into the continuous casting device and providing improved profile control of the cast metal product. In various embodiments, the controller is mechanically coupled to the at least one dam for improved durability and reliability of connection and control of the at least one dam under difficult operating conditions (e.g., in close proximity to the molten metal and in close proximity to the continuous casting device). In certain embodiments, the dam system includes a sensor associated with the at least one dam, the sensor capable of detecting a temperature of the molten metal downstream of the at least one dam. The controller can control the vertical position of the at least one dam based on the detected temperature to provide a desired temperature distribution of the molten metal entering the continuous casting device, which in turn improves profile control of the cast metal product. In certain embodiments, the dam system comprises a plurality of dams, each of which can be independently controlled by the controller for improved control of the metal distribution and/or temperature distribution of the molten metal supplied to the continuous casting device. Various other advantages and benefits may be realized with the systems and methods provided herein, and the advantages set forth above should not be considered limiting.

Figures 1 to 3 illustrate a continuous casting system (100) having a continuous casting device (102) and a metal supply system (104) according to embodiments.

In the examples of FIGS. 1-3, the continuous casting device (102) is a twin roll caster (106) having a pair of rolls (108A, 108B) as movable molds. Each of the rolls (108A, 108B) rotates about an axis as indicated by arrows (110A, 110B). A gap (112) is formed between the rolls (108A, 108B), and during casting, molten metal is supplied into the gap (112) by a metal supply system (104). As the metal contacts the rolls (108A, 108B), heat is rapidly extracted and the metal begins to solidify. The solidified metal is further compressed as it passes through the gap (112) between the rolls (108A, 108B) and exits the continuous casting device (102) as a cast metal product (114) (e.g., sheet, plate, shade, etc.) (represented by arrows (144)). While the continuous casting device (102) is illustrated as a twin roll caster (106), in other embodiments, the continuous casting device (102) may be any of a variety of other types of continuous casting devices desired, including but not limited to belt casters, block casters, and/or other casting devices desired.

The metal supply system (104) typically includes an injector (116), a supply vessel (118), and a dam system (120). The injector (116) includes a tip (122) through which molten metal can be introduced into a gap (112) of a casting device (102). In the embodiments illustrated in FIGS. 1 and 2, the injector (116) includes sidewalls (128) as well as a lower wall (124) and an upper wall (126) that converge toward the tip (122). However, the particular shape and profile of the injector (116) should not be considered limiting, and the injector (116) may have any number of desired shapes and profiles suitable for supplying molten metal to the casting device (102). As some non-limiting examples, the sidewalls (128) can be convergent, parallel or divergent, and the walls (124, 126) can be convergent or parallel. The injector (116) can have additional walls and/or shapes as desired.

A supply vessel (118) (e.g., a tundish) is upstream of the injector (116) and typically defines a receiving area (130) (see FIGS. 2 and 3) for initially receiving the molten metal. In the embodiment best illustrated and depicted in FIG. 2, the supply vessel (118) includes an inlet (132) capable of initially receiving the molten metal, and a main portion (134) between the inlet (132) and the injector (116). However, the shape and profile of the supply vessel (118) should not be considered limiting, and the supply vessel (118) and/or the receiving area (130) may have various shapes, sizes, and profiles as desired.

The dam system (120) includes at least one dam (136) and a controller (138) operably coupled to at least one dam (136). In some embodiments, the dam system (120) includes a single dam, while in other embodiments, the dam system (120) includes a plurality of dams. In the embodiments of FIGS. 1 and 2, the dam system (120) includes five dams (136A-136E). In embodiments having a plurality of dams (136), each dam (136) may be optionally operably coupled to a controller (138). As best illustrated in FIG. 2, the dams (136) of the dam system (120) may be provided across the width of the receiving area (130) of the supply vessel (118) (e.g., transversely with respect to the direction of flow of the molten metal). In certain embodiments, the dams (136) need not be provided across the entire width of the receiving area (130). In some non-limiting examples, the dams (136) are provided across at least 30% of the width of the receiving area (130), for example at least 40% of the width of the receiving area (130), for example at least 50% of the width of the receiving area. However, in other embodiments, the dams (136) may be provided across any range of the width of the receiving area (130), as desired. As discussed in more detail below, the dam(s) (136) may be positioned vertically within the receiving area (130) (represented by arrows (141) in FIG. 1) to control the flow of molten metal to the injector (116). FIG. 3 illustrates non-limiting examples of dams (136A-136E) at various vertical positions within the receiving area (130).

A controller (138) is operatively coupled to the dam(s) (136) to control the vertical position of the dam(s) (136) within the receiving area (130). In embodiments having a plurality of dams (136), the controller (138) can control the vertical position of each dam (136) independently of the other dams (136). In other embodiments, the controller (138) can jointly control the vertical position of two or more dams (136) as desired. Controlling the vertical positions of the dam(s) (136) can control the distribution of molten metal to the injector (116) and thus the casting device (102), which can in turn control the profile of the cast metal product (114). In certain embodiments and as discussed below, controlling the vertical positions of the dam(s) (136) can control the temperature distribution in the molten metal provided to the injector (116), which can control the profile of the cast metal product (114). As illustrated in FIG. 3, where the dam system (120) includes a plurality of dams (136), the controller (138) can control the dams (136) to be in a variety of vertical positions as desired, wherein the vertical position of one dam (136) need not be the same as another dam (136).

The controller (138) may include one or more processing units and/or one or more memory devices. The processing unit of the controller may be any suitable processing device or combination of devices including, but not limited to, one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), programmable logic controllers (PLCs), field programmable gate arrays (FPGAs), processors, controllers, microcontrollers, microprocessors, other electronic units, and/or combinations thereof. The one or more memory devices of the controller (138) may be any machine-readable medium that can be accessed by the processor, including but not limited to any type of long-term, short-term, volatile, nonvolatile, or other storage medium, and is not limited to any particular type of memory or number of memories, or the type of media on which the memory is stored. Also, as used herein, the terms 'storage medium', 'storage' or 'memory' can refer to one or more memories for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage media, optical storage media, flash memory devices, and/or other machine-readable media for storing information. The term 'machine-readable medium' includes, but is not limited to, portable or fixed storage devices, optical storage devices, wireless channels, and/or various other storage media capable of containing or carrying and storing instructions(s) and/or data. The above examples of processing devices and memory devices should not be considered limiting, and the controller (138) can include various types of processing devices and/or memory devices as desired.

In certain embodiments, the controller (138) optionally includes an associated user interface, including but not limited to a graphical user interface, to enable the controller (138) to obtain information from a user and/or provide information to a user. In such embodiments, the user interface may be on the controller (138) itself, or may be remote from the controller (138), such as but not limited to another location within the casting system (100). Additionally or alternatively, the controller (138) may optionally include various communication modules to enable the controller (138) to receive and/or transmit information as desired. Non-limiting examples of communication modules may include systems and mechanisms that enable wired communications and/or wireless communications (e.g., short-range, cellular, Wi-Fi, Bluetooth®, Bluetooth Low Energy (BLE), etc.).

In certain embodiments, the controller (138) includes at least one actuator (140) for mechanically and operatively coupling the controller (138) to the dam(s) (136) of the dam system (120). The actual mechanical coupling between the actuator (140) and the dams (136) of FIG. 1 is omitted for clarity of the drawing. In embodiments having multiple dams (136), each dam (136) may optionally include a dedicated actuator (140) that may facilitate independent control of the dams (136). In certain embodiments, the mechanical coupling provided by the actuator (140) can provide improved durability and reliability of the connection between the controller (138) and the dam (136) to control the vertical position of the dam (136) under difficult operating conditions (e.g., in close proximity to molten metal and in close proximity to the continuous casting device (102). The at least one actuator (140) can be any of a variety of devices, mechanisms or systems desired. In one non-limiting embodiment, the actuator (140) comprises a motor having a plurality of flexible shafts driven by the motor.

Referring again to FIG. 1 , in various embodiments, in addition to the dam(s) (136) and the controller (138), the dam system (120) includes at least one temperature sensor (142) associated with at least one dam (136). The at least one temperature sensor can be any of a variety of suitable devices or mechanisms suitable for detecting a temperature of the molten metal downstream of the at least one dam (136). In some embodiments, the at least one temperature sensor (142) is provided upstream of the tip (122) of the injector (116), although the particular location of the sensor (142) should not be considered limiting.

In certain embodiments, at least one temperature sensor (142) is communicatively coupled to a controller (138), and the controller (138) can control the vertical position of at least one dam (136) based on a detected temperature from the corresponding temperature sensor (142). In embodiments having a plurality of dams (136), the dam system (120) can include a plurality of temperature sensors (142), each of which can be associated with a particular dam (136). By way of example and as illustrated in FIG. 2 , the dam system (120) can include five temperature sensors (142A through 142E), each of which is associated with a corresponding dam (136A through 136E). In this embodiment, the controller (138) can control the vertical position of each dam (136A through 136E) based on the temperature detected by each associated temperature sensor (142A through 142E). As a non-limiting example, the controller (138) can raise the dam (136C) based on the temperature detected by the temperature sensor (142C) being below a predetermined value to increase the metal flow and temperature of the molten metal downstream of the dam (136C). Such independent control of the dams (136A through 136E) based on their corresponding temperature sensors (142A through 142E) can enable the controller (138) to distribute the molten metal with a desired flow and/or temperature distribution for a desired profile of the cast metal product.

Optionally, the dam system (120) includes at least one system sensor (146) for detecting a parameter of the continuous casting system (100). The at least one system sensor (146) can be communicatively coupled to a controller (138), and the controller (138) can selectively control one or more of the dams (136) based on information detected by the at least one system sensor (146). The number, type, location and parameters detected by the at least one system sensor (146) should not be considered limiting. In the illustrated embodiment, a single system sensor (146) is provided, and the system sensor (146) is a flatness sensor (148). In this embodiment, the flatness sensor (148) can detect a flatness of the cast metal product (114), and the controller (138) can selectively control the dams (136) based on the detected flatness from the flatness sensor (148). In certain embodiments, the flatness (or cross-sectional) profile detected by the flatness sensor (148) may be used to predict the temperature profile of the cast metal product (114) and/or the molten metal. Various other types of sensors may be used as at least one system sensor (146), as desired.

Figures 4 through 7 illustrate other examples of a continuous casting system (400) having a continuous casting device (402) and a metal supply system (404) according to embodiments. Similar to the casting device (102), the casting device (402) is a twin roll caster (406) having a frame (407) for supporting rolls similar to the rolls (108). However, in Figures 4 through 7, the rolls of the twin roll caster (406) are omitted for clarity of the drawings.

The metal supply system (404) is similar to the metal supply system (104) and includes an injector (416), a supply container (418), and a dam system (420). The injector (416) is substantially similar to the injector (116) except that the injector (416) has a different profile. The supply container (418) is substantially similar to the supply container (118) except that the shape and profile of the supply container (418) and the receiving area (430) of the supply container (418) are different compared to the supply container (118).

The dam system (420) is similar to the dam system (120) and includes a plurality of dams (436A-436E) and a controller (438) operably coupled to the dams (436A-436E) for vertically positioning the dams (436A-436E) within the receiving area (430). As best illustrated in FIGS. 5-7 , similar to the controller (138), the controller (438) includes an actuator (440) mechanically coupling the controller (438) to each of the dams (436A-436E). In the embodiments illustrated in FIGS. 4-7 , the actuator (440) includes a motor (441) and a plurality of flexible shafts (443A-443E). The motor (441) is illustrated as being supported on the frame (407); however, in other embodiments, the motor (441) may be provided in various locations as desired. Each of the flexible shafts (443A through 443E) mechanically and operatively connects the motor (441) to its corresponding dam (436A through 436E) such that the dams (436A through 436E) are independently controllable.

Referring again to FIGS. 1-3, a method of controlling distribution of molten metal into a continuous casting device (102) using a metal supply system (104) is discussed in detail below. In certain embodiments, the method comprises supplying molten metal, such as a molten aluminum alloy, to a supply vessel (118). In some embodiments, the method comprises initially receiving molten metal in an inlet (132) of the supply vessel (118) such that the molten metal flows from the inlet (132) to the main portion (134). The method comprises controlling distribution of the metal to the injector (116) by at least partially blocking the flow of molten metal through the receiving region (130) of the supply vessel (118) using one or more dams (136). The method includes the steps of introducing molten metal into a gap (112) of a casting device (102) through a tip (122) of an injector (116) and casting the molten metal into a cast metal product (114) using the casting device (102).

In certain embodiments, the method comprises controlling the vertical positions of the dams (136) using the controller (138) to control the metal distribution and/or temperature distribution of the molten metal flowing into the gap (112). In some embodiments, the method comprises vertically raising a particular dam (136) to increase the flow of metal and/or increase the temperature of the molten metal downstream of the particular dam (136) and vertically lowering the particular dam (136) to decrease the flow of metal and/or decrease the temperature of the molten metal downstream of the particular dam (136). In some embodiments, the step of controlling the vertical positions of the dams (136) comprises independently controlling each dam (136) of the plurality of dams (136).

In some embodiments, the step of controlling the dams (136) includes the steps of receiving a temperature of the molten metal downstream of the particular dam (136) from a corresponding temperature sensor (142), and controlling the particular dam (136) based on the detected temperature from the corresponding temperature sensor (142). As a non-limiting example, the method may include the steps of controlling the dam (136A) based on the detected temperature from the temperature sensor (142A), controlling the dam (136B) based on the detected temperature from the temperature sensor (142B), controlling the dam (136C) based on the detected temperature from the temperature sensor (142C), controlling the dam (136D) based on the detected temperature from the temperature sensor (142D), and/or controlling the dam (136E) based on the detected temperature from the temperature sensor (142E).

In various embodiments, controlling the dams (136) based on the temperatures detected from the temperature sensors (142) may include comparing the detected temperatures to predetermined temperatures corresponding to a particular profile of the cast metal product (114), and controlling the dams (136) based on any differences between the detected temperatures and the predetermined temperatures. In certain embodiments, controlling the dams (136) may include controlling the dams (136) such that the molten metal supplied to the casting device has a desired temperature profile or distribution across the width of the molten metal flowing into the gap (112). The desired temperature profile or distribution may be a uniform temperature profile or distribution in some embodiments; however, in other embodiments, the method includes controlling the dams (136) to provide a non-uniform temperature profile or distribution across the width of the molten metal flowing into the gap (112). In some embodiments, the method optionally includes predicting, by the controller (138), a temperature profile of the cast metal product (114) and/or the molten metal based on the detected flatness profile of the cast metal product. Optionally, the method can include comparing the predicted temperature profile to a desired temperature profile and controlling the vertical position of one or more of the dams (136) based on a difference between the predicted temperature profile and the desired temperature profile.

Optionally, the method includes controlling the vertical position of one or more dams (136) based on information from at least one system sensor (146). As a non-limiting example, the method may include receiving, by the controller (138), a detected flatness profile of the cast metal product from at least one system sensor (146), comparing the detected flatness profile to a desired flatness profile, and controlling one or more dams (136) based on any difference between the detected flatness profile and the desired flatness profile.

As noted, the systems and methods provided herein can improve distribution of molten metal to a continuous casting device, such as a twin roll caster, which can improve quality control of the cast metal product. The systems and methods provided herein can also improve control in other difficult operating conditions in close proximity to the molten metal and in close proximity to the continuous casting device. Various other benefits and advantages can be realized with the systems and methods discussed herein.

Examples

A collection of exemplary embodiments, including at least some explicitly listed as 'Examples', is provided below to provide additional illustration of various exemplary embodiments according to the concepts described herein. These examples are not intended to be mutually exclusive, comprehensive, or limiting; the present disclosure is not limited to these exemplary examples, but rather includes all possible modifications and variations within the scope of the presented claims and their equivalents.

Example 1. A metal supply system, comprising: an injector for dispensing molten metal into a movable mold; a supply vessel defining a receiving area positioned upstream of the injector and configured to receive the molten metal; and a dam system; wherein the dam system comprises at least one dam positionable within the receiving area; and a controller operably coupled to the at least one dam, the controller being configured to vertically position the at least one dam within the receiving area to control a flow of molten metal from the receiving area to the injector.

Example 2. A metal supply system of any preceding or subsequent example or combination of examples, wherein the controller is mechanically coupled to the at least one dam.

Example 3. A metal supply system of any of the preceding or subsequent examples or combinations of examples, wherein the dam system comprises a temperature sensor configured to detect a temperature of the molten metal downstream of the at least one dam, the temperature sensor being communicatively coupled to the controller, the controller being configured to control the vertical position of the at least one dam based on the temperature of the molten metal detected by the temperature sensor.

Example 4. A metal supply system of any of the preceding or subsequent examples or combinations of examples, wherein the controller is configured to predict a temperature profile of the cast metal product based on the detected flatness profile of the cast metal product, compare the predicted temperature profile to a predetermined temperature profile, and control the vertical position of the at least one dam based on a difference between the predicted temperature profile and the predetermined temperature profile.

Example 5. A metal supply system according to any preceding or subsequent example or combination of examples, wherein the temperature sensor is configured to detect a temperature of the molten metal upstream of a tip of the injector.

Example 6. A metal supply system of any of the preceding or subsequent examples or combinations of examples, wherein said at least one dam comprises a plurality of dams provided transversely to the direction of flow of molten metal from said receiving region to said injector across at least a portion of the width of said receiving region, and wherein said controller is operably coupled to each dam of said plurality of dams and configured to independently control the vertical position of each dam of said plurality of dams.

Example 7. A metal supply system of any of the preceding or subsequent examples or combinations of examples, wherein the dam system further comprises a plurality of temperature sensors, each temperature sensor of the plurality of temperature sensors being communicatively coupled to the controller and configured to detect a temperature of the molten metal downstream of a corresponding dam of the plurality of dams, and wherein the controller is configured to independently control the vertical position of each dam of the plurality of dams based on the detected temperature of the molten metal detected from the corresponding temperature sensor.

Example 8. A metal supply system according to any preceding or subsequent example or combination of examples, wherein the plurality of dams comprises at least five dams.

Example 9. A twin roll casting system, comprising a twin roll casting machine and a metal supply system of any of the preceding or subsequent examples or combinations of examples.

Example 10. A twin roll casting system of any preceding or subsequent example or combination of examples, further comprising a flatness sensor downstream of the twin roll casting machine configured to detect a flatness profile of a cast metal product downstream of the twin roll casting machine, the flatness sensor being communicatively coupled to the controller, the controller being configured to at least partially control a vertical position of the at least one dam based on the detected flatness profile.

Example 11. A dam system for a metal supply system, the dam system comprising: a plurality of dams; and a controller operably coupled to each dam of the plurality of dams, the controller configured to control a vertical position of each dam of the plurality of dams independently of the remaining dams of the plurality of dams.

Example 12. A dam system of any preceding or subsequent example or combination of examples, further comprising a plurality of temperature sensors, each temperature sensor of the plurality of temperature sensors being configured to detect a temperature of molten metal downstream of the corresponding dam.

Example 13. A dam system of any preceding or subsequent examples or combinations of examples, wherein each temperature sensor of the plurality of temperature sensors is communicatively coupled to the controller, and the controller is configured to control each dam of the plurality of dams based on the detected temperature of the molten metal detected from the corresponding temperature sensor.

Example 14. A dam system of any preceding or subsequent examples or combinations of examples, wherein the controller is mechanically coupled to each dam of the plurality of dams.

Example 15. A dam system of any preceding or subsequent example or combination of examples, wherein the controller is configured to control the vertical position of each dam of the plurality of dams to control a temperature profile of the molten metal.

Example 16. A method for controlling distribution of molten metal into a continuous casting device, the method comprising: at least partially blocking a flow of molten metal from a receiving region to an injector using at least one dam in the receiving region; detecting a temperature of the molten metal downstream of the at least one dam; and controlling a vertical position of the at least one dam based on the detected temperature.

Example 17. A method according to any preceding or subsequent example or combination of examples, wherein the at least one dam comprises a plurality of dams, and wherein the step of detecting the temperature of the molten metal comprises the step of detecting the temperature of the molten metal downstream of each dam of the plurality of dams.

Example 18. A method according to any preceding or subsequent example or combination of examples, wherein the step of controlling the vertical position of the at least one dam comprises independently controlling the vertical position of each dam of the plurality of dams based on the detected temperature corresponding to a particular dam of the plurality of dams.

Example 19. A method according to any preceding or subsequent example or combination of examples, wherein said at least one dam comprises a plurality of dams, and wherein the step of controlling the vertical position of said at least one dam comprises the step of controlling the vertical position of each dam of said plurality of dams.

Example 20. A method according to any preceding or subsequent example or combination of examples, further comprising the steps of: predicting a temperature profile of the cast metal product based on the detected flatness profile of the cast metal product, comparing the predicted temperature profile to a predetermined temperature profile, and controlling the vertical position of the at least one dam based on a difference between the predicted temperature profile and the predetermined temperature profile.

The inventive subject matter of the embodiments is specifically set forth herein so as to satisfy the statutory requirements, but such description is not necessarily intended to limit the scope of the claims. The claimed inventive subject matter may be embodied in other ways, may involve different elements or steps, and may be used in connection with other existing or future technologies. This description should not be construed as implying any particular order or arrangement between the various steps or elements, except where the order of the arrangement of individual steps or elements is explicitly set forth. Among other things, directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “front,” and “rear” are intended to refer to the orientation of the components and directions as illustrated and described in the drawing (or drawings) to which they refer. Throughout this disclosure, reference numerals with letters refer to specific instances of an element, and reference numerals without letters refer to the elements generally or collectively. Thus, as an example (not shown in the drawings), device '12A' refers to an instance of a class of devices, which may be collectively referred to as devices '12', any one of which may be generally referred to as device '12'. In the drawings and description, like reference numerals are intended to represent like elements. As used herein, the meanings of the articles 'a', 'an' and 'the' include singular and plural references unless the context clearly dictates otherwise.

In this description, reference is made to alloys identified by AA numbers and other related designations such as 'series' or '7xxx'. For an understanding of the numbering systems most commonly used to name and identify aluminum and its alloys, see the 'International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys' published by the Aluminum Association or the 'Aluminum Association Alloy Designations and Chemical Composition Limits Registry Record for Aluminum Alloys in Cast and Ingot Forms'.

As used herein, a plate generally has a thickness greater than about 15 mm. For example, a plate can refer to an aluminum product having a thickness greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm. As used herein, a shade (also referred to as sheet plate) generally has a thickness of from about 4 mm to about 15 mm. For example, a shade can have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm. As used herein, sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, the sheet can have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).

As used herein, the terms "cast metal product", "cast product", "cast aluminum alloy product" and the like are used interchangeably and refer to products produced by direct chill casting (including direct chill cavity casting), semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous casting machine), electromagnetic casting, hot top casting, or any other casting method.

The embodiments described above are merely possible examples of implementations and are merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the embodiment(s) described above without substantially departing from the spirit and principles of the present disclosure. All such variations and modifications are intended to be included within the scope of the present disclosure, and all possible claims directed to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Furthermore, although certain terms are used in this specification as well as in the claims that follow, they are used in a generic and descriptive sense only, and not for the purpose of limiting the described embodiments or the claims that follow.

Claims (20)

As a metal supply system,
An injector that distributes molten metal into a movable mold;
a supply vessel defining a receiving area positioned upstream of the injector and configured to receive said molten metal; and
A dam system comprising:
At least one dam positionable within said receiving area; and
A metal supply system comprising: a controller operatively coupled to at least one dam, the controller configured to vertically position the at least one dam within the receiving area to control the flow of molten metal from the receiving area to the injector; A metal supply system in accordance with claim 1, wherein the controller is mechanically coupled to at least one dam. A metal supply system in accordance with claim 1, wherein the dam system comprises a temperature sensor configured to detect a temperature of the molten metal downstream of the at least one dam, the temperature sensor being communicatively coupled to the controller, and the controller being configured to control a vertical position of the at least one dam based on the temperature of the molten metal detected by the temperature sensor. In the third aspect, the metal supply system is configured to predict a temperature profile of the cast metal product based on the detected flatness profile of the cast metal product, compare the predicted temperature profile with a predetermined temperature profile, and control the vertical position of the at least one dam based on a difference between the predicted temperature profile and the predetermined temperature profile. A metal supply system in claim 3, wherein the temperature sensor is configured to detect the temperature of the molten metal upstream of the tip of the injector. A metal supply system in accordance with claim 1, wherein said at least one dam comprises a plurality of dams provided transversely to the direction of flow of the molten metal from said receiving area to said injector across at least a portion of the width of said receiving area, and wherein said controller is operably coupled to each dam of said plurality of dams and configured to independently control the vertical position of each dam of said plurality of dams. In the sixth paragraph, the dam system further comprises a plurality of temperature sensors, each temperature sensor of the plurality of temperature sensors being communicatively coupled to the controller and configured to detect a temperature of the molten metal downstream of a corresponding dam among the plurality of dams, and the controller being configured to independently control the vertical position of each dam among the plurality of dams based on the detected temperature of the molten metal detected from the corresponding temperature sensor. A metal supply system in claim 6, wherein the plurality of dams include at least five dams. A twin roll casting system comprising the metal supply system of claim 1 and a twin roll casting machine. A twin roll casting system, in claim 9, further comprising a flatness sensor downstream of the twin roll casting machine configured to detect a flatness profile of the cast metal product downstream of the twin roll casting machine, the flatness sensor being communicatively coupled to the controller, the controller being configured to at least partially control the vertical position of the at least one dam based on the detected flatness profile. As a dam system for a metal supply system, said dam system comprises:
multiple dams; and
A dam system, comprising: a controller operably coupled to each dam of said plurality of dams, said controller configured to control a vertical position of each dam of said plurality of dams independently of the remaining dams of said plurality of dams. A dam system in accordance with claim 11, further comprising a plurality of temperature sensors, each temperature sensor of the plurality of temperature sensors being configured to detect a temperature of molten metal downstream of the corresponding dam. In the 12th paragraph, each temperature sensor of the plurality of temperature sensors is communicatively coupled to the controller, and the controller is configured to control each dam of the plurality of dams based on the detected temperature of the molten metal detected from the corresponding temperature sensor. A dam system in accordance with claim 11, wherein the controller is mechanically coupled to each dam of the plurality of dams. A dam system in accordance with claim 11, wherein the controller is configured to control the vertical position of each dam of the plurality of dams to control the temperature profile of the molten metal. A method for controlling the distribution of molten metal into a continuous casting device, said method comprising:
A step of at least partially blocking the flow of molten metal from the receiving area to the injector using at least one dam in the receiving area;
detecting the temperature of the molten metal downstream of at least one of the dams; and
A method comprising: controlling the vertical position of at least one dam based on the detected temperature. A method in accordance with claim 16, wherein the at least one dam comprises a plurality of dams, and the step of detecting the temperature of the molten metal comprises the step of detecting the temperature of the molten metal downstream of each dam of the plurality of dams. A method in accordance with claim 17, wherein the step of controlling the vertical position of at least one dam comprises the step of independently controlling the vertical position of each dam of the plurality of dams based on the detected temperature corresponding to a specific dam among the plurality of dams. A method in claim 16, wherein the at least one dam comprises a plurality of dams, and the step of controlling the vertical position of the at least one dam comprises the step of controlling the vertical position of each dam of the plurality of dams. A method in accordance with claim 16, further comprising the steps of: predicting a temperature profile of the cast metal product based on the detected flatness profile of the cast metal product; comparing the predicted temperature profile with a predetermined temperature profile; and controlling the vertical position of the at least one dam based on a difference between the predicted temperature profile and the predetermined temperature profile.

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