Dinascope-Sort

Dinascope-Sort System for registration and analysis of Mechanical movements of the Mould in the wide range of frequencies for evaluation of Oscillation Mechanisms condi-tion and technological parameters of the casting process for Billet Casters

Purpose

Dinascope-Sort System is designed for:
Caster maintenance planning depending on wear of different parts of Oscillation Mechanism, de-fined by the change in the spectrum of mechanical oscillations in the wide range of frequencies;
  • Detection of mismatch in movement of any select point on the Mould surface with regards to the Caster radius (technological axis) by way of measuring the angular speeds and linear movements along the three axises;
  • Evaluation of lubrication property of the Powder being used through measuring the friction of the Billet in the Mould, separately for dry (Coulomb) and viscous friction. This feature is unique for this type of systems;
  • Evaluation of alterations in the casting technological parameters, including calculation of zero rela-tive Mould-Billet speed depending on dry friction value, generation of recommendation for se-lection of optimal speed ratio between oscillation and casting. This feature is unique for this type of systems.

Main principles of the System

Dinascope-Sort System consist ofIndustrial Computer, Monitor, high temperature cabling, interface for data collection and several triaxial high precision (≤0.015 mm) movement sensors. Number of  sensors may vary from one to three or more, depending on operation conditions, Mould and Oscillation Mechanism design. They are fixed either on the Mould or on the select moving parts of the Oscillation
Mechanism with the help of threading, thus, making their mounting and maintenance easy (See Pic. 1).
Signals from the Sensor are processed by special algorithm that includes frequency ranges up to few hundreds of Hertz. These ranges reveal condition and wear of different parts of Oscillation Mechanism.

Programmed calculations of the main parameters and definition of their permissible deviations

Mechanical Parameters.

Trajectories of movement of select points on the surface of the Mould
Movements of these select points on the Mould surface are calculated with precision of ≤0.015 mm,
particularly, those on the bottom edge of the copper plates, considering their linear and angular movements with their simultaneous isometric visualization on the screen (Pic. 2). Also, the actual deviations of the trajectory from that defined by the Caster radius (projected value) as well as that of the Mould movement without billet (Mould setting) is calculated.

Detection of faults by the calculated trajectories of Mould movements

  • Optimal setting;
  • Spring failure;
  • Worn out or damaged bearings;
  • Excessive wear of Moulds Copper Plates.
Vibratory Oscillations

  • Low frequency spectrum along all three axises;
  • Resonance frequency area;
  • High frequency spectrum along all three axises.
Fault detection by intensity alteration of different ranges of the spectrum
  • Excessive wear of Moulds Copper Plates;
  • Failure of different parts of the Oscillation Mechanism;
  • Wear or damage of springs;
  • Wear or damage of bearings;
  • Bearing lubrication fault.
 Technological Parameters of Casting
  • Negative Mould movement speed interval vis-à-vis billet;Positive Mould movement speed interval vis-à-vis billet;
  • Zero Mould movement speed interval vis-à- vis billet Mould movement together withbillet;
  • Mould advance;
  • Mould oscillation symmetry;
  • dry (Coulomb) Mould friction;
  • Power efficiency ratio;
  • Motor load ratio;
  • Optimal value of casting speed and Mould oscillation frequency.
Finding optimal technological conditions ofcasting using measured technological parameters

  • Selection of optimal Powder for differentcasting speeds;
  • Setting of the optimal casting speeds  for different grades steel and billet sizes.
Economic Effect

Economic effect of Dinascope-Sort System utilization is generated through the following  advantages:
  • Considerable reduction of surface defects in Billets, such as non-metallic inclusions, transverse, longitudinal and mesh-like cracks etc.;
  • Extended life of the Mould by way of better precision in Oscillation Mechanism setting and optimal casting speed selection;
  • Considerable reduction in maintenance expenses by way of monitoring of Oscillation Mechanism and overall casting conditions that allows in-process tunings and adjustments as well as better shut-down planning;
  • Prevention of breakdowns caused by failure of different parts of Oscillation Mechanism through alarms generated by the System; 
  • Capacity enhancement through casting speed increase with minimal risk due to better process control and monitoring.