Method for casting metal strip with edge control
Systems and apparatus for continuously casting thin strip where one or more expansion rings are positioned within at least one of a pair of casting rolls, and automatically measuring a thickness of the cast strip close to the first side edge of the strip using at least one sensor. If the thickness measured is too thin, automatically decreasing the radial dimension of the expansion ring arranged in close proximity to the first side edge to cause the cylindrical tube to contract and increase the thickness of the cast strip during casting. If the thickness measured indicates that the thickness of the cast strip is too thick, automatically increasing the radial dimension of the expansion ring arranged in close proximity to the first side edge to cause the cylindrical tube to expand and reduce the thickness of the cast strip during casting.
1. A casting roll control system with adjustable circumference control for use in a twin roll caster for producing cast strip metal, comprising:
a casting roll including a casting surface formed by a cylindrical tube;
a logic controller;
a first expansion ring disposed within the cylindrical tube within 450 mm of an edge of the casting surface, the first expansion ring having at least one heating element and at least one temperature sensor adapted to provide signals indicative of expansion ring temperature, the at least one temperature sensor being coupled to the logic controller, the first expansion ring being formed of a material that expands an outer diameter of the first expansion ring when heated by the at least one heating element, thereby expanding an outer diameter of the casting surface corresponding to a location of the first expansion ring; and
a plurality of strip thickness sensors adapted to provide output signals indicative of a thickness of a cast strip capable of being arranged to make thickness measurements across a width of a cast strip in a line substantially perpendicular to a casting direction including an edge thickness and being coupled to the logic controller;
wherein the logic controller is configured with instructions stored in non-volatile memory to receive thickness measurements from the strip thickness sensors and temperature measurements from the at least one temperature sensor, fit a curve to the thickness measurements, determine a target edge thickness of the cast strip based on the curve, determine a delta thickness as a difference between the measured edge thickness and the target edge thickness and cause an amount of power applied to the at least one heating element to be adjusted to reduce the delta thickness.
2. The casting roll control system of claim 1 , wherein the curve fitted to the thickness measurements is a polynomial function defining a parabola.
3. The casting roll control system of claim 1 , wherein the target edge thickness is determined as an extrapolation of the curve fitted to the thickness measurements.
4. The casting roll control system of claim 1 , wherein the target edge thickness is determined as an extrapolation of the curve fitted to the thickness measurements with a positive or negative offset added.
5. The casting roll control system of claim 1 , further comprising a power controller coupled between the logic controller and the at least one heating element, wherein the power controller increases and decreases an amount of power being applied to the at least one heating element in response to a signal from the logic controller.
6. The casting roll control system of claim 1 , wherein the logic controller is configured to periodically update the curve fitted to the thickness measurements based on new measurements, and periodically update the target edge thickness based on the updated curve.
7. The casting roll control system of claim 1 , wherein the logic controller is configured to continuously update the curve fitted to the thickness measurements based on new measurements, and continuously update the target edge thickness based on the updated curve.
8. The casting roll control system of claim 1 , wherein the logic controller is configured with instructions stored in non-volatile memory to cause an amount of power applied to the at least one heating element to be adjusted by determining a target temperature of the first expansion ring based on the delta thickness, measuring the temperature of the first expansion ring, determining a delta temperature as a difference between the measured temperature with the target temperature, and causing an amount of power applied to the at least one heating element to be adjusted to reduce the delta temperature.
9. The casting roll control system of claim 1 , further comprising a second expansion ring disposed within 450 mm of an edge of the casting surface opposite the first expansion ring and controlled in a likewise manner.
10. The casting roll control system of claim 1 , wherein the first expansion ring is disposed inwardly from the edge of the casting surface.
11. A casting roll control system with adjustable circumference control for use in a twin roll caster for producing cast strip metal, comprising:
a casting roll including a casting surface formed by a cylindrical tube;
a logic controller;
a first expansion ring disposed within the cylindrical tube and under a step which forms a shoulder of the casting surface, the first expansion ring having at least one heating element and at least one temperature sensor adapted to provide signals indicative of expansion ring temperature, the at least one temperature sensor being coupled to the logic controller, the first expansion ring being formed of a material that expands an outer diameter of the first expansion ring when heated by the at least one heating element, thereby expanding an outer diameter of the casting surface corresponding to a location of the first expansion ring; and
a plurality of strip thickness sensors adapted to provide output signals indicative of a thickness of a cast strip capable of being arranged to make thickness measurements across a width of a cast strip in a line substantially perpendicular to a casting direction including an edge thickness and being coupled to the logic controller;
wherein the logic controller is configured with instructions stored in non-volatile memory to receive thickness measurements from the strip thickness sensors and temperature measurements from the at least one temperature sensor, fit a curve to the thickness measurements, determine a target edge thickness of the cast strip based on the curve, determine a delta thickness as a difference between the measured edge thickness and the target edge thickness and cause an amount of power applied to the at least one heating element to be adjusted to reduce the delta thickness.
12. The casting roll control system of claim 11 , wherein the curve fitted to the thickness measurements is a polynomial function defining a parabola.
13. The casting roll control system of claim 11 , wherein the target edge thickness is determined as an extrapolation of the curve fitted to the thickness measurements.
14. The casting roll control system of claim 11 , wherein the target edge thickness is determined as an extrapolation of the curve fitted to the thickness measurements with a positive or negative offset added.
15. The casting roll control system of claim 11 , further comprising a power controller coupled between the logic controller and the at least one heating element, wherein the power controller increases and decreases an amount of power being applied to the at least one heating element in response to a signal from the logic controller.
16. The casting roll control system of claim 11 , wherein the logic controller is configured to periodically update the curve fitted to the thickness measurements based on new measurements, and periodically update the target edge thickness based on the updated curve.
17. The casting roll control system of claim 11 , wherein the logic controller is configured to continuously update the curve fitted to the thickness measurements based on new measurements, and continuously update the target edge thickness based on the updated curve.
18. The casting roll control system of claim 11 , wherein the logic controller is configured with instructions stored in non-volatile memory to cause an amount of power applied to the at least one heating element to be adjusted by determining a target temperature of the first expansion ring based on the delta thickness, measuring the temperature of the first expansion ring, determining a delta temperature as a difference between the measured temperature with the target temperature, and causing an amount of power applied to the at least one heating element to be adjusted to reduce the delta temperature.
19. The casting roll control system of claim 11 , further comprising a second expansion ring disposed under a step opposite the first expansion ring and controlled in a likewise manner.
20. The casting roll control system of claim 11 , wherein the first expansion ring is aligned with an edge of the casting surface.