WO2025006321A1

WO2025006321A1 - Carriage position control for belt casting machines

Info

Publication number: WO2025006321A1
Application number: PCT/US2024/034895
Authority: WO
Inventors: Dennis P. Chadwick; Heinz Becker
Original assignee: Novelis Inc.
Priority date: 2023-06-26
Filing date: 2024-06-21
Publication date: 2025-01-02

Abstract

A belt casting system for casting metal such as aluminum and aluminum alloys includes a first carriage and a second carriage that together define a casting cavity. The second carriage may be supported by the first carriage. In some embodiments, the first carriage may include a support that engages the second carriage and controls a distance between the first carriage and the second carriage.

Description

CARRIAGE POSITION CONTROL FOR BELT CASTING MACHINES

REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/510,190, filed on June 26, 2023, and entitled CARRIAGE POSITION CONTROL FOR BELT CASTING MACHINES, the content of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

[0002] This application relates to continuous belt casters, and, more specifically, to systems and methods for controlling carriages of continuous belt casters.

BACKGROUND

[0003] Continuous belt casters, such as twin belt casters, single belt casters, and recirculating block casters, are commonly used to produce cast metal articles from molten metal including but not limited to aluminum and aluminum alloys. In continuous belt casters, a casting cavity is formed between continuously moving casting surfaces which are supported on carriages (e.g., a lower carriage and an upper carriage). During the casting process, molten metal is introduced into the casting cavity (typically on a continuous basis). Heat is removed from the metal by the elongated belt surfaces and the metal solidifies into the metal article, which is continuously withdrawn from the casting cavity by the moving casting surfaces. Traditionally, each carriage of the belt caster has been independently supported on a frame and independently oriented. However, such traditional techniques may have issues with position control such as carriages that are not parallel, thereby leading to quality issues in the metal substrate being cast.

SUMMARY

[0004] Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0005] According to certain embodiments, a continuous belt casting system includes a first carriage and a second carriage. The first carriage and the second carriage define a casting cavity, and the second carriage is supported by the first carriage.

[0006] According to some embodiments, a continuous belt casting system includes an upper carriage at least partially defining a casting cavity and a lower carriage at least partially defining the casting cavity. The lower carriage includes a positioning system engaged with the upper carriage, and the positioning system controls a distance between the upper carriage and the lower carriage.

[0007] According to various embodiments, a method of belt casting includes supporting an upper carriage on a lower carriage, and the upper carriage and the lower carriage define a casting cavity.

[0008] Various implementations described herein can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0010] FIG. 1 illustrates a continuous belt casting system with a carriage positioning system according to embodiments.

[0011] FIG. 2 illustrates a portion of the continuous belt casting system of FIG. 1.

[0012] FIG. 3 illustrates another portion of the continuous belt casting system of FIG. 1.

[0013] FIG. 4 illustrates another portion of the continuous belt casting system of FIG. 1.

[0014] FIG. 5 illustrates another portion of the continuous belt casting system of FIG. 1. [0015] FIG. 6 illustrates another portion of the continuous belt casting system of FIG. 1.

[0016] FIG. 7 illustrates another portion of the continuous belt casting system of FIG. 1.

[0017] FIG. 8 illustrates another portion of the continuous belt casting system of FIG. 1.

DETAILED DESCRIPTION

[0018] Described herein are systems and methods for controlling carriage positions of a belt casting system. In certain embodiments, the systems and methods described herein include a first (e.g., lower) carriage of the belt casting system that supports a second (e.g., upper) carriage of the belt casting system. In some embodiments, the first carriage includes a positioning system for controlling a position of the second carriage relative to the first carriage, and the positioning system may support the second carriage on the first carriage. In various embodiments, supporting the second carriage on the first carriage may allow for improved control of a casting cavity defined by the carriages. As examples, supporting the second carriage on the first carriage may allow for a desired orientation of the first carriage relative to the second carriage to be maintained, and deflections that the carriages may experience may be the same for both carriages, thereby providing a uniform casting cavity. In various embodiments, the positioning system allows for improved control of the position of the first carriage relative to the second carriage, and the position may be adjustable to provide a casting cavity with a desired profile.

[0019] In some embodiments, the positioning system includes one or more supports, and a height of the supports may be adjustable to control the distance between the first carriage and the second carriage. The one or more supports may be controlled independently or jointly as desired. The one or more supports may be various types of supports as desired, and in some non-limiting examples, the one or more supports may be support pins.

[0020] In certain embodiments, the positioning system may position the second carriage relative to the first carriage such that the casting cavity converges (gets progressively thinner) from the entrance of the casting cavity towards the exit of the casting cavity. In various embodiments, the positioning system may be a self-centering positioning system providing lateral position control of the first carriage relative to the second carriage. Various other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting. [0021] FIGS. 1-8 illustrate an example of a continuous belt casting system 100 according to embodiments. The continuous belt casting system 100 generally includes a first (or lower) carriage 102A and a second (or upper) carriage 102B. The second carriage 102B may be in an open or non-casting position (FIGS. 1 and 2) or a closed or casting position (FIG. 3) relative to the first carriage 102 A. In various embodiments, the second carriage 102B may be in the open position during initial installation, maintenance, and/or as otherwise desired other than during a casting process, and the second carriage 102B may be in the closed position during casting and/or operation of the continuous belt casting system 100. As discussed in detail below, the first carriage 102 A may support the second carriage 102B in the closed position.

[0022] In the closed position and as illustrated in FIG. 3, the carriages 102A-B together define a casting cavity 104 having an entrance 106 and an exit 108. Each carriage 102A-B supports an endless belt (not shown) having an elongated surface and the carriages 102A-B further include devices or mechanisms for driving the endless belts such that they rotate in a casting direction and move through the casting cavity 104 during casting. The carriages 102A-B may also include other components or equipment, such as but not limited to coolant nozzles for controlling heat transfer through the endless belts. Non-limiting examples of additional components for the carriages 102A-B are described U.S. Pat. No. 4,061,178 to Sivilotti et al., issued on Dec. 6, 1977, and U.S. Pat. No. 4,193,440 to Thorburn et al., issued on Mar. 18, 1980, both of which are hereby incorporated by reference in their entireties.

[0023] Edge dams (not shown) may be provided at each side of the continuous belt casting system 100 to enclose the casting cavity 104 at its edges.

[0024] During casting, the endless casting belts are run at substantially the same speed such that the casting cavity 104 forms a moving mold that is static relative to metal that is introduced into the casting cavity 104 and as the metal passes through the casting cavity 104. The metal may be various metals as desired, and in some embodiments, the metal is aluminum or an aluminum alloy in the Ixxx series, 2xxx series, 3xxx series, 4xxx series, 5xxx series, 6xxx series, 7xxx series, 8xxx series and/or any other aluminum or aluminum alloy as desired. As the metal advances through the casting cavity 104, heat from the metal is transferred through the endless belts, and the molten metal becomes progressively solidified. The molten metal may be partially or fully solidified before it reaches the exit 108 and may emerge from the exit 108 as a continuous, solid cast metal substrate or slab. [0025] Referring back to FIG. 1, the continuous belt casting system 100 may include a frame 110 supporting at least the first carriage 102 A. In certain embodiments, the frame 110 may support the second carriage 102B while the second carriage 102B is in the open position.

[0026] In various embodiments, the frame 110 may include a frame positioning system 112 for selectively moving the second carriage 102B between the open position and the closed position. The frame positioning system 112 includes one or more actuators 114 that are attached to the second carriage 102B via a support feature 116. In the embodiment illustrated, the actuators 114 are hydraulic lifting cylinders; however, in other embodiments, the actuators 114 may be various devices or mechanisms suitable for raising or lowering the second carriage 102B as desired. As best illustrated in FIGS. 4 and 5, the support feature 116 may allow for freedom of motion and/or movement of the second carriage 102B relative to the actuators 114. As discussed in detail below, the freedom of motion and/or movement allows for the second carriage 102B to be supported by the first carriage 102A when the second carriage 102B is in the closed position. In the embodiment illustrated, the support feature 116 includes a pin 118 retained within an elongated slot 120. The pin 118 retained within the elongated slot 120 allows for coupling and decoupling of the second carriage 102B with the actuators 114 based on whether the pin 118 is in the slot 120. However, in other embodiments, other engagement features 116 may be utilized as desired

[0027] As mentioned, in the closed position, the second carriage 102B is supported by the first carriage 102 A. In certain embodiments, the first carriage 102 A includes a positioning system 122 that couples and/or supports the second carriage 102B on the first carriage 102A. In various embodiments, the positioning system 122 of the first carriage 102 A includes one or more supports 124 for engaging and supporting the second carriage 102B. In the embodiment illustrated, the one or more supports 124 are support pins; however, in other embodiments, other types of supports 124 and/or supports 124 with other shapes or profiles may be utilized as desired. In the embodiment illustrated, the positioning system 122 includes four supports 124A-D, and two supports 124A-B are provided proximate to the entrance 106 and two support points 124C-D are provided proximate to the exit 108. However, the number and location of the supports 124 should not be considered limiting.

[0028] The supports 124 may have various shapes or profiles as desired. In certain embodiments, the supports 124 engage a corresponding engagement feature 126 on the second carriage 102B. Optionally, the supports 124 and the engagement features 126 may be keyed or otherwise configured to mate when the second carriage 102B is in the closed position. In some embodiments, the supports 124 and the engagement features 126 may be self-centering engagement features, which may provide lateral position control to position the second carriage 102B relative to the first carriage 102 A. Referring to FIGS. 6-7, in the embodiment illustrated, the supports 124 have a domed portion 128 and the engagement features 126 include a convex portion 130, and the domed portion 128 engaged with the convex portion 130 allows for selfcentering of the second carriage 102B on the first carriage 102A and/or consistent lateral position control of the second carriage 102B relative to the first carriage 102 A. Other supports 124 and/or engagement features 126 may be utilized as desired.

[0029] In various embodiments, a height of the supports 124 is adjustable such that the distance between the second carriage 102B and the first carriage 102A (and thus a height and/or profile of the casting cavity 104) may be adjusted as desired. As non-limiting examples, the supports 124 may be controlled such that the cavity 104 has a generally constant height, such that the cavity 104 converges towards the exit 108, such that the cavity 104 diverges towards the exit 108, and/or as otherwise desired. In embodiments where the cavity 104 has a non- uniform height, the height of one support 124 may be different from the height of another support 124. In embodiments with a plurality of supports 124, the supports 124 may be controlled independently or jointly in any combination as desired. The supports 124 may be adjusted via various mechanisms or devices as desired, and in some embodiments, the supports 124 may be adjusted via one or more actuators. In one non-limiting example, the supports 124 are adjusted via hydraulic actuators, although they need not be in other embodiments.

[0030] In some embodiments, the positioning system 122 optionally includes a controller 132. The controller 132 may include one or more processing units and/or one or more memory devices. The processing unit may be various suitable processing devices or combinations of devices including but not limited to one or more application specific integrated circuits, digital signal processors, digital signal processing devices, programmable logic devices, field programmable gate arrays, processors, controllers, micro-controllers, microprocessors, other electronic units, and/or a combination thereof. The one or more memory devices 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 to be limited to any particular type of memory or number of memories, or type of media upon which memory is stored. Moreover, as disclosed herein, the term “storage medium,” “storage” or “memory” can represent one or more memories for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage mediums, optical storage mediums, flash memory devices and/or other machine readable mediums 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 mediums capable of storing that contain or carry instruction(s) and/or data. In certain embodiments, the controller 132 optionally includes an associated user interface, including but not limited to a graphical user interface or a human machine interface, such that the controller 132 may obtain information from a user and/or provide information to the user. In such embodiments, the user interface and/or human machine interface may be on the controller 132 itself or may be at a location remote from the controller 132.

[0031] The controller 132 may be communicatively coupled with the actuators of the one or more supports 124 such that the controller 132 may control the height of the one or more supports 124. In some embodiments, the controller 132 may control the one or more supports 124 based on feedback or input from a user. Additionally, or alternatively, the controller 132 optionally may control the one or more supports 124 based on data from one or more sensors, such as but not limited to one or more sensors measuring a profile of the cast metal substrate and/or one or more sensors measuring a height or profile of the casting cavity 104 and/or the supports 124.

[0032] Optionally, the positioning system 122 includes one or more sensors 134 (see, e.g., FIG. 2) for detecting or measuring a height of the casting cavity 104 and/or a height of one or more supports 124. The sensors 134 may be various suitable sensors as desired, such as but not limited to, position sensors, optical sensors, laser sensors, combinations thereof, and/or other sensors as desired. The number, location, and/or type of sensor utilized as the one or more sensors 134 should not be considered limiting.

[0033] When the sensors 134 are included with the positioning system 122, the controller 132 may be communicatively coupled to the one or more sensors 134 such that the controller 132 receives the position and/or height data. In certain embodiments, based on the data from the one or more sensors 134, the controller 132 may control one or more supports 124 such that the casting cavity 104 has a desired profile. As a non-limiting example, the controller 132 may receive the height data about a support 124, compare the measured height data to a desired height for the support 124 (e.g., corresponding to a profile of the casting cavity 104 and/or profile of the cast metal substrate), and control the height of the support 124 based on a difference between the desired height and the measured height. Various other controls may be implemented based on feedback from the one or more sensors 134 as desired and to produce a metal substrate with a desired profile.

[0034] A method of casting a metal substrate using the belt casting system 100 may include providing the second carriage 102B in the closed position such that the second carriage 102B is supported by the first carriage 102A. The method may include controlling a profile of the casting cavity 104 defined by the carriages 102A-B using the positioning system 122. In some embodiments, controlling the profile of the casting cavity 104 includes adjusting or otherwise controlling a height of one or more supports 124 that support the second carriage 102B on the first carriage 102 A. In one non-limiting example, the method includes controlling the one or more supports 124 such that supports 124 proximate to the entrance 106 of the casting cavity 104 have a height greater than a height of supports 124 proximate to the exit 108 of the casting cavity 104. In other embodiments, the supports 124 are controlled to provide a casting cavity 104 with any profile as desired. In some embodiments, the method includes controlling the one or more supports 124 independently or jointly as desired.

[0035] In various embodiments, the method includes introducing molten metal into the casting cavity 104. The method may include monitoring a height of the casting cavity 104 and/or a height of one or more supports 124 using the one or more sensors 134 and controlling the supports 124 based on the data from the one or more sensors 134. In such embodiments, the supports 124 may be controlled before molten metal is introduced into the casting cavity 104 and/or during casting as desired such that the belt casting system 100 provides a cast metal substrate with a desired profile. Various other methods and/or processes may be implemented as desired using the belt casting system 100.

[0036] A collection of exemplary embodiments is provided below, including at least some explicitly enumerated as an “Illustration” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0037] Illustration 1. A belt casting system comprising a first carriage and a second carriage, wherein the first carriage and the second carriage define a casting cavity, and wherein the second carriage is supported by the first carriage. [0038] Illustration 2. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein the first carriage is a lower carriage and the second carriage is an upper carriage.

[0039] Illustration 3. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein the first carriage is configured to support a first endless belt and the second carriage is configured to support a second endless belt.

[0040] Illustration 4. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein the first carriage comprises a positioning system that supports the second carriage on the first carriage.

[0041] Illustration 5. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein the positioning system comprises a support on the first carriage, wherein the support is engaged with the second carriage and such that the second carriage is supported by the first carriage, and wherein a height of the support is adjustable.

[0042] Illustration 6. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein the support comprises a first engagement feature and the second carriage comprises a second engagement feature, and wherein the first engagement feature and the second engagement feature are self-centering engagement features.

[0043] Illustration 7. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein the positioning system comprises a plurality of supports engaged with the second carriage, and wherein a height of each support of the plurality of supports is adjustable.

[0044] Illustration 8. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein each support of the plurality of supports is independently adjustable.

[0045] Illustration 9. A belt casting system comprising: an upper carriage at least partially defining a casting cavity; and a lower carriage at least partially defining the casting cavity, wherein the lower carriage comprises a positioning system engaged with the upper carriage, wherein the positioning system controls a distance between the upper carriage and the lower carriage.

[0046] Illustration 10. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein the positioning system comprises a support engaging a corresponding engagement feature on the upper carriage, wherein the support wherein the support couples the upper carriage on the lower carriage.

[0047] Illustration 11. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein a height of the support is adjustable.

[0048] Illustration 12. The belt casting system of any preceding or subsequent illustration or combination of illustrations, further comprising: a sensor for detecting a position of the support; and a controller for controlling the position of the support based at least partially on the detected position from the sensor.

[0049] Illustration 13. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein the support and the corresponding engagement feature are self-centering engagement features.

[0050] Illustration 14. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein positioning system comprises a plurality of supports engaged with the upper carriage, and wherein a height of each support of the plurality of supports is adjustable.

[0051] Illustration 15. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein the height of each support is independently controlled.

[0052] Illustration 16. The belt casting system of any preceding or subsequent illustration or combination of illustrations, wherein the support comprises a support pin.

[0053] Illustration 16. A method of belt casting, the method comprising supporting an upper carriage on a lower carriage, wherein the upper carriage and the lower carriage define a casting cavity.

[0054] Illustration 17. The method of any preceding or subsequent illustration or combination of illustrations, further comprising controlling a profile of the casting cavity by controlling a support of the lower carriage, wherein the support couples the upper carriage on the lower carriage.

[0055] Illustration 18. The method of any preceding or subsequent illustration or combination of illustrations, wherein the lower carriage comprises an entrance support proximate to an entrance of the casting cavity and an exit support proximate to an exit of the casting cavity, wherein the entrance support and the exit support both support the upper carriage on the lower carriage, and wherein the method comprises controlling a profile of the casting cavity by controlling a height of the exit support and a height of the entrance support.

[0056] Illustration 19. The method of any preceding or subsequent illustration or combination of illustrations, wherein the method comprises controlling the height of the exit support independently from controlling the height of the entrance support.

[0057] Illustration 20. The method of any preceding or subsequent illustration or combination of illustrations, further comprising introducing molten metal into the casting cavity.

[0058] As used herein, the terms “invention,” “the invention,” “this invention,” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0059] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “5xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0060] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0061] The subject matter of embodiments of the present disclosure is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “vertical,” “horizontal,” “lateral,” “longitudinal,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing. [0062] The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0063] The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.

Claims

CLAIMS That which is claimed:

1. A belt casting system comprising a first carriage and a second carriage, wherein the first carriage and the second carriage define a casting cavity, and wherein the second carriage is supported by the first carriage.

2. The belt casting system of claim 1, wherein the first carriage is a lower carriage, and the second carriage is an upper carriage.

3. The belt casting system of claim 1, wherein the first carriage is configured to support a first endless belt and the second carriage is configured to support a second endless belt.

4. The belt casting system of claim 1, wherein the first carriage comprises a positioning system that supports the second carriage on the first carriage.

5. The belt casting system of claim 4, wherein the positioning system comprises a support on the first carriage, wherein the support is engaged with the second carriage and such that the second carriage is supported by the first carriage, and wherein a height of the support is adjustable.

6. The belt casting system of claim 5, wherein the support comprises a first engagement feature and the second carriage comprises a second engagement feature, and wherein the first engagement feature and the second engagement feature are self-centering engagement features.

7. The belt casting system of claim 4, wherein the positioning system comprises a plurality of supports engaged with the second carriage, and wherein a height of each support of the plurality of supports is adjustable.

8. The belt casting system of claim 7, wherein each support of the plurality of supports is independently adjustable.

9. A belt casting system comprising: an upper carriage at least partially defining a casting cavity; and a lower carriage at least partially defining the casting cavity, wherein the lower carriage comprises a positioning system engaged with the upper carriage, wherein the positioning system controls a distance between the upper carriage and the lower carriage.

10. The belt casting system of claim 9, wherein the positioning system comprises a support engaging a corresponding engagement feature on the upper carriage, wherein the support pin couples the upper carriage on the lower carriage.

11. The belt casting system of claim 10, wherein a height of the support is adjustable.

12. The belt casting system of claim 11, further comprising: a sensor for detecting a position of the support; and a controller for controlling the position of the support based at least partially on the detected position from the sensor.

13. The belt casting system of claim 10, wherein the support and the corresponding engagement feature are self-centering engagement features.

14. The belt casting system of claim 9, wherein the positioning system comprises a plurality of supports engaged with the upper carriage, and wherein a height of each support of the plurality of supports is adjustable.

15. The belt casting system of claim 14, wherein the height of each support is independently controlled.

16. A method of belt casting, the method comprising supporting an upper carriage on a lower carriage, wherein the upper carriage and the lower carriage define a casting cavity.

17. The method of claim 16, further comprising controlling a profile of the casting cavity by controlling a support of the lower carriage, wherein the support couples the upper carriage on the lower carriage.

18. The method of claim 16, wherein the lower carriage comprises an entrance support proximate to an entrance of the casting cavity and an exit support proximate to an exit of the casting cavity, wherein the entrance support and the exit support both support the upper carriage on the lower carriage, and wherein the method comprises controlling a profile of the casting cavity by controlling a height of the exit support and a height of the entrance support.

19. The method of claim 18, wherein the method comprises controlling the height of the exit support independently from controlling the height of the entrance support.

20. The method of claim 16, further comprising introducing molten metal into the casting cavity.