Claims:

1. A mould assembly (100) for a continuous casting process, the assembly (100) comprising:
a mould (1) defining a casting zone in an inner surface, and at least one groove (2) extending on an outer surface of the mould (1);
an oiler plate (15) positioned at a neck region (9) of the mould (1) enclosing neck region (9) of the mould (1);
wherein, the oiler plate (15) is defined with a first aperture (13);
an optic fiber cable (3) accommodated in the first aperture (13) and the groove (2) of the mould (1);
wherein the optic fiber cable (3) includes a plurality of sensors (3a) to measure at least one of temperature and strain in the mould (1).

2. The assembly (100) as claimed in claim 1 comprises, a second aperture (5) defined along the neck region (9) of the mould (1) wherein, the second aperture (5) extends over the mould (1).

3. The assembly (100) as claimed in claim 2 wherein, the second aperture (5) is defined proximal to the first aperture (13) of the oiler plate (15) and cooperates with the at least one groove (2) defined on the mould (1).

4. The assembly (100) as claimed in claim 1 wherein, the mould (1) is in a tube-shaped configuration.

5. The assembly (100) as claimed in claim 1 wherein, the at least one groove (2) extends along the first axis (A-A) of the mould (1).

6. The assembly (100) as claimed in claim 1 wherein, a depth of the at least one groove (2) ranges from 2 mm to 8 mm.

7. The assembly (100) as claimed in claim 1 wherein, the groove (2) extends along the length of the mould (1) in at least one of straight line or a spiral line configuration encompassing an outer circumference of the mould (1).

8. The assembly (100) as claimed in claim 1 comprises, a heat resistant tube (4) defined with a first region (4a) and a second region (4b) wherein, the heat resistant tube (4) is defined by a 90-degree bend between the first region (4a) and the second region (4b).

9. The assembly (100) as claimed in claim 8 wherein, the first region (4a) of the heat resistant tube (4) is removably housed inside the second aperture (5) and the second region (4b) of the heat resistant tube (4) is positioned on the neck region (9) of the mould (1).

10. The assembly (100) as claimed in claim 1 comprises, a connector (6) connected to the fiber optic cable (3) wherein, the connector (6) facilitates a connection between a control unit (8) and the fiber optic cable (3).
, Description:TECHNICAL FIELD

Present disclosure relates in general to a field of material science and metallurgy. Particularly, but not exclusively, the present disclosure relates to a mould assembly for a continuous casting process. Further embodiments of the present disclosure disclose a configuration of the mould for accommodating an optic fiber cable to measure temperature and strain in the mould.

BACKGROUND OF THE DISCLOSURE

Continuous casting is the process whereby molten metal is solidified into a semifinished billet, bloom, slab, or tube for subsequent rolling in finishing mills. Liquid steel flows from a ladle, through a tundish into the mould. The mould imparts a final shape to the molten metal. The liquid metal freezes against the walls of the water-cooled mould to form a solid outer shell. The mould is an open-ended box or tube-shaped structure containing a water-cooled inner lining fabricated from a high purity copper alloy. Once the liquid steel refining process is completed during steelmaking, the liquid steel contained in the ladle is normally sent to a continuous casting machine. The steel is poured from the ladle to a tundish and then from the tundish into a water-cooled copper mould which induces the formation of a thin, solidified shell. The function of the mould is to produce and stabilize a solid shell and contain the semi-solid or liquid or molten metal within. If the mould system does not work properly, a breakouts can take place and the hot liquid steel core can burst open, pouring liquid steel onto the machine. Such scenarios result serve damage to the machinery may halt the manufacturing process for a prolonged period of time. Consequently, temperature measurement of a continuous casting mould becomes crucial for monitoring various operational aspects or quality in the casting process.

Patent application “WO2012168005” discloses a method for measuring the height of the meniscus in the continuous casting mould using fiber optic cables. The application discloses the aspect of controlling the outflow of liquid metal into the mould based on volume of liquid flowing into the mould, measured by a flow sensor. However, the method is limited to slab moulds. Configuring tube moulds for temperature measurement is difficult due to the construction of the tube mould. The tube mould is suspended from a neck region inside a stainless-steel jacket. Water at high speeds flows between an outer surface of the tube and the stainless-steel jacket. It is therefore difficult to access the outer surface of the tube for installing temperature measurement sensors.

The present disclosure is directed to overcome one or more limitations stated above or any other limitation associated with the conventional arts.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of the prior art are overcome by a method and a product as claimed and additional advantages are provided through the method as described in the present disclosure.

Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non limiting embodiment of the disclosure, a mould assembly for a continuous casting process is disclosed. The assembly includes a mould defining a casting zone in an inner surface, and at least one groove extending on an outer surface of the mould. An oiler plate is positioned at a neck region of the mould enclosing neck region of the mould where, the oiler plate is defined with a first aperture. Further, an optic fiber cable is accommodated in the first aperture and the groove of the mould where, the optic fiber cable includes a plurality of sensors to measure at least one of temperature and/or strain in the mould.

In an embodiment, a second aperture is defined along the neck region of the mould where, the second aperture extends along a first axis of the mould.

In an embodiment, the second aperture is defined proximal to the first aperture of the oiler plate and cooperates with the at least one groove defined on the mould.

In an embodiment, the mould is in a tube-shaped configuration and at least one groove extends along the first axis of the mould.

In an embodiment, the first aperture of the oiler plate extends along a second axis perpendicular to the first axis of the mould.

In an embodiment, a depth of the at least one groove ranges from 2 mm to 7 mm and the groove extends through-out the length of the mould in at least one of straight line or a spiral line configuration encompassing an outer circumference of the mould.

In an embodiment, a heat resistant tube is defined with a first region and a second region where, the heat resistant tube is defined by a 90-degree bend between the first region and the second region.

In an embodiment, the first region of the heat resistant tube is removably housed inside the second aperture of the oiler plate and the second region of the heat resistant tube is positioned on the top region of the mould.

In an embodiment, a connector is connected to the fiber optic cable where, the connector facilitates a connection between a control unit and the fiber optic cable.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

The novel features and characteristics of the disclosure are set forth in the appended description. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

Fig. 1 illustrates a side view of a mould assembly with an optic fiber cable coupled to a control unit, according to an exemplary embodiment of the present disclosure.

Fig. 2 illustrates a schematic perspective view of the mould with the optic fiber cable, according to an exemplary embodiment of the present disclosure.

Fig. 3 illustrate a side view and sectional view of a top region of the mould, according to an exemplary embodiment of the present disclosure.

Fig. 4 shows a slot for drawing out the optic fiber cable, according to an exemplary embodiment of the present disclosure.

Fig 5 shows a perspective view of a heat resistant tube, according to an exemplary embodiment of the present disclosure.

Fig. 6 illustrates a top view of the mould with the optic fiber cable, according to an exemplary embodiment of the present disclosure.

Figure 7 shows a graphical representation of temperature measurements by the optic fiber from different locations on the mould, according to an exemplary embodiment of the present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the mould assembly illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the description of the disclosure. It should also be realized by those skilled in the art that such equivalent methods do not depart from the scope of the disclosure. The novel features which are believed to be characteristic of the disclosure, as to method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the particular form disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the disclosure.

The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a method that comprises a list of acts does not include only those acts but may include other acts not expressly listed or inherent to such method. In other words, one or more acts in a method proceeded by “comprises… a” does not, without more constraints, preclude the existence of other acts or additional acts in the method.

Embodiments of the present disclosure disclose a mould assembly for a continuous casting process. The tube mould is suspended from a neck region inside a stainless-steel jacket. Water at high speeds flows between an outer surface of the tube and the stainless-steel jacket. It is therefore difficult to access the outer surface of the tube for installing temperature measurement sensors.

According to various embodiments of the disclosure, a mould assembly for a continuous casting process is disclosed. The assembly includes a mould defining a casting zone in an inner surface, and at least one groove extending on an outer surface of the mould. An oiler plate is positioned at a neck region of the mould enclosing the neck region of the mould where, the oiler plate is defined with a first aperture. A second aperture is defined along the neck region of the mould where, the second aperture extends along a first axis of the mould. The second aperture is defined proximal to the first aperture of the oiler plate and cooperates with the at least one groove defined on the mould. A heat resistant tube is defined with a first region and a second region where, the heat resistant tube is defined by a 90-degree bend between the first region and the second region. The first region of the heat resistant tube is removably housed inside the second aperture of the oiler plate and the second region of the heat resistant tube is positioned on the top region of the mould. Further, an optic fiber cable is accommodated in the first aperture and the groove of the mould where, the optic fiber cable includes a plurality of sensors to measure at least one of temperature and /or strain in the mould.

The following paragraphs describe the present disclosure with reference to Figs. 1 to 6.

Fig. 1 illustrates a side view of a mould assembly (100) with an optic fiber cable (3), and Fig. 2 illustrates a perspective view of the mould assembly (100) with the optic fibre cable (3). The mould assembly (100) may be of tubular in shape for continuous casting of molten metal and manufacturing of billet. The mould assembly (100) includes a tube-shaped mould (1) of a metallic material including but not limited to copper. The mould (1) may be defined by an inner surface and an outer surface. The inner surface of the mould (1) may form the casting zone for casting or solidifying the molten metal whereas the outer surface of the mould (1) may be abutted with a cooling jacket (20). The mould (1) may be an open-ended box or tube-shaped structure with the cooling jacket (20). The mould (1) may be used to solidify an outer layer of the molten metal to form a tube-shaped billet. The cooling jacket (20) may be provisioned around the mould (1). The cooling jacket (20) may include a plurality of fluid flow lines for accommodating the flow of a coolant including but not limited to water or any other industrial grade coolant mixed with water in adequate proportions. In an embodiment, any known method or assembly may be configured to the surroundings of the mould (1) for cooling the mould (1). Further, continuous casting involves, solidifying molten metal into a semifinished billet including but not limited to the shape of a tube or, square or rectangle or round for subsequent rolling in finishing mills. Molten metal may be directed to flow from a ladle, through a tundish into the mould (1). The mould (1) may impart a final shape to the molten metal and the molten metal may freeze against the walls of the water-cooled mould (1) to form a solid shell. The mould (1) may produce and stabilize a solid shell to contain the liquid or molten metal within the shell. Further, a top end of the mould (1) may be defined by a neck region (9) and the mould may be extended along a longitudinal axis (A-A) herein referred to as the first axis (A-A). The mould (1) may be suspended from the neck region (9) inside the cooling jacket (20). The mould assembly (100) may also include an oiler plate (15) and a top plate (14). The dimensions of the oiler plate (15) may be equivalent or similar to that of the cooling jacket (20). The oiler plate (15) may be defined with a central cut-out with dimensions equivalent to the mould (1) and the oiler plate may also be defined with a first aperture (13). The oiler plate (15) may be positioned on the mould (1) such that the opening of the mould (1) is accommodated by the oiler plate (15) and the neck region (9) of the mould (1) is enclosed by the mould (1). Further, a top plate (14) may be provided on the oiler plate (15). The top plate (14) may be configured with similar dimensions as that of the oiler plate (15) and may also be configured to enclose the neck region (9) of the mould (1).

The mould assembly (100) may further be configured to accommodate an optic fiber cable (3) for temperature and strain measurement along a length of the mould (1). The configuration of the mould assembly (100) accommodating the optic fiber cable (3) is explained with greater detail below. The mould (1) may be defined with at least one groove (2) (further referred to as “the groove”) defined on the outer surface of the mould (1) and along the first axis (A-A) of the mould (1). The groove (2) may extend throughout the length of the mould (1) and may be configured to accommodate the optic fiber cable (3). The groove (2) may extend through-out the length of the mould (1) in at least one of straight line or a spiral line configuration encompassing the outer circumference of the mould (1). In an embodiment, the groove (2) may be defined to the mould (1) by machining the outer surface of the mould (1) and the groove (2) may be machined with a depth ranging from 2 mm to 8 mm. The groove (2) may further be filled with a sealant for enclosing the optic fiber cable (3). Further, the optic fibre cable (3) may include a plurality of Fiber Braggs Grating (FBG) sensors that may be positioned are pre-defined locations through-out the length of the optic fiber cable (3) encompassing the mould (1).

Fig. 3 illustrates a side view of the top end of the mould (1) and Fig. 4 shows a side view of the top end of the mould (1) defined with a slot (10) for drawing out the optic fiber cable (3). A second aperture (5) may be defined along the neck region (9) of the mould (1). The second aperture (5) may be defined to extend along the first axis (A-A) of the mould (1). The second aperture (5) defined along the neck region (9) may unite with the groove (2) defined to the outer surface of the mould (1). Further, the second aperture (5) may extend to define a slot (10) at the top end of the mould (1). The slot (10) may be of equal dimensions as that of the second aperture (5). In an embodiment, the slot (10) may be curved for accommodating the optic fiber cable (3) and the curvature of the optic fiber cable (3) as the optic fiber cable (3) extends out of the mould (1). The optic fiber cable (3) may be drawn out from the groove (2) of the mould (1) through the second aperture (5) and the slot (10) defined to the neck region (9) of the mould (1).

Further, a heat resistant tube (4) may be removably housed within the second aperture (5). Fig 5 shows a perspective view of a heat resistant tube (4). The heat resistant tube (4) may be defined with a first region (4a) and a second region (4b). The heat resistant tube (4) may be defined by a 90-degree bend between the first region (4a) and the second region (4b). The first region (4a) of the heat resistant tube (4) may be removably housed inside the second aperture (5) and the second region (4b) of the heat resistant tube (4) may be positioned on the neck region (9) of the mould (1). In an embodiment, the slot (10) may be defined with dimensions equivalent to the second region (4b) of the heat resistant tube (4). The slot (10) may be defined to accommodate the second region (4b) of the heat resistant tube (4). The slot (10) may be defined such that the second region (4b) of the heat resistant tube (4b) is flush with a top surface of the mould (1). The heat resistant tube (4) may be pre-bent with a radius ranging from 2 mm to 10 mm. In an embodiment, the pre-bent heat resistant tube (4) has a 90-degree bend angle between the first region (4a) and the second region (4b) enables the fiber optic cable (3) to be drawn out of the mould (1) without breaking the fiber optic cable (3). The heat resistant tube (4) may provide the required support for the optic fiber cable (3) to sustain the load from the oiler plate (15) and the top plate (14) and may prevent any damage to the optic fiber cable (3). The optic fiber cable (3) from the groove (2) may be drawn out of the mould (1) through the heat resistant tube (4). The optic fiber cable (3) may extend though the first region (4a) of the heat resistant tube (4) and may be drawn out to the top surface of the mould (1) through the second region (4b) of the heat resistant tube (4).

Fig. 6 illustrates a top view of the mould (1) with the optic fiber cable (3). The optic fiber cable (3) from the heat resistant tube (4) may be accommodated or drawn out of the oiler plate (15) through the first aperture (13) defined in the oiler plate (15). The first aperture (13) of the oiler plate (15) may extend along a second axis (B-B) perpendicular to the first axis (A-A) of the mould (1). Further, the second aperture (5) is defined proximal to the first aperture (13) of the oiler plate (15) and cooperates with the groove (2) defined on the mould (1). The first aperture (13) may be defined to lie proximal to the second region (4b) of the heat resistant tube (4) such that the optic fiber cable (3) from the second region (4b) of the heat resistant tube (4) is drawn out through the first aperture (13) of the oiler plate (15). Further, the type of optic fiber cable (3) fibre may be selected to withstand load from the top plate (14) and the oiler plate (15). In an embodiment, a single mode silica optic fiber cable (3) coated with a polymer coating may be used. The optic fiber cable (3) may be protected with a non-fraying braided fiberglass, which has a smaller gauge and can pass through the top plate (14) and oiler plate (15) without snapping. The optic fiber cable (3) may be spliced (12) and may be drawn out of the mould assembly (100). The optic fiber cable (3) may further be attached to a connector (6). The connector (6) may facilitate a connection between the optic fiber cable (3) and an optical interrogator (7). The connector (6) may be provided with easy coupling and de-coupling of the optic fiber cable (3) with the optical interrogator (7). The optical interrogator (7) may further be coupled to a control unit (8), a computer or a processor for measuring the temperature and strain in the mould (1).

The optical interrogator (7) may send a laser pulse of predefined wavelength to the plurality of FBG sensors (3a), and the optical interrogator (7) may also be configured to receive and analyse reflected wavelength from the plurality of FBG sensors (3a). The optical interrogator (7) may further be connected to the control unit (8), which receives the reflected wavelength from the optical interrogator (7). In an embodiment, the control unit (8) may be configured to convert the reflected wavelength received from each of the plurality of FBG sensors (3a) into a proportional strain or temperature value. One of the important features of the FBG sensors (3a) is that refractive index and pitch of the grating of the FBG sensors (3a) changes when the FBG sensors (3a) are strained or when there exists any variation in temperature. The refractive index and pitch of the grating of the FBG sensors (3a) changes proportionately with the change in temperature. Thereby, the wavelength of the laser pulse that is reflected by the FBG sensors (3a) also changes proportionately with the change in the refractive index and pitch of the grating of the FBG sensors (3a). The optical interrogator (7) that is connected to the plurality of FBG sensors (3a) through the optic fiber cable (3) transmits a laser pulse of predetermined wavelength. The transmitted laser pulse travels through the optic fiber cable (3) to the plurality of FBG sensors (3a). The refractive index and the grating of the FBG sensors (3a) are configured to reflect a certain wavelength of the transmitted laser pulse known as the braggs wavelength. The reflected wavelength or the braggs wavelength is received by the optical interrogator (7). Under normal conditions, the reflected wavelength corresponds to refractive index and the grating of the FBG sensors (3a). Further, when there exists variation in temperature, the refractive index and pitch of the grating of the FBG sensors (3a) changes proportionately with the change in temperature. Accordingly, with the change in the refractive index and pitch of the grating of the FBG sensors (3a), the wavelength of the laser pulse that is reflected by the FBG sensors (3a) also changes proportionately. This change in wavelength of the reflected laser pulse from the FBG sensors (3a) is received by the optical interrogator (7) and is further transmitted to a control unit (8). The control unit (8) converts the reflected wavelength into suitable values. Figure 7 shows a graphical representation of temperature measurements by the optic fiber cable (3) from different locations on the mould (1). As seen from the graph, the temperature variation from each of the FBG sensors (3a) may be measured for a prolonged period of time. Further, if any deviation in temperature is detected beyond a threshold limit, the coolant flow rate, or the coolant temperature from the cooling jacket (20) may be suitably varied for achieving the required mould temperature (1) during manufacturing of billets. Also, any deformation in the mould (1) structure may also be detected through the FBG sensors (3a).

In an embodiment, the above, mould assembly (100) provides a plug and play system for measuring the temperature and/or strain in the moulds (1) of the billet caster of continuous casting system.

In an embodiment, configuring the mould assembly (100) for accommodating the optic fiber cable (3) is simple and cost-effective.

In an embodiment, the mould assembly (100) of the above-mentioned configuration enables an accurate measurement of the temperature and/or strain throughout the billet casting mould (1) or the tube-shaped mould (1).

Equivalents:

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Referral Numerals

Referral Numerals Description
1 Mould
2 Groove
3 Optic fiber cable
3a FBG sensors
4 Heat resistant tube
4a First region of the heat resistant tube
4b Second region of the heat resistant tube
5 Second aperture
6 Connector
7 Optical interrogator
8 Processor/control unit/computer
9 Neck region of the mould
10 Slot
12 Spliced region of the optic fiber cable
13 First aperture
14 Top plate
15 Oiler plate