Development of Automated Control System for Continuous Casting

Context. Today, automated continuous casting control systems are developing rapidly, as process of manufacturing billets (products) of same size from metal in casting mold in mass production has long been outdated and “continuous casting stage” is coming. This process is suitable for non-ferrous metals and steel. However, each time during development, task of improving quality of resulting billet arises, which directly depends on optimizing efficiency and reliability of automated systems themselves. Optimization is key stage in development process, as it is aimed at ensuring accuracy and stability of casting process, which includes development of parametric model and accurate algorithms that ensure optimal temperature, metal pouring rate, oscillation frequency, oscillation amplitude, metal level in crystallizer, and position of position of industrial bucket stopper for each casting stage. In particular, this problem has not yet been fully solved in literature known to authors, so it is necessary to formulate problem and develop algorithm for system operation for specific safety casting unit. Objective. The aim of study is to develop automated control system to ensure accuracy and stability of casting process. Method. The developed control system for continuous casting plant is based on proposed parametric model, which is formalized on basis of set theory. The model takes into account key parameters for particular casting process: metal pouring rate, oscillation frequency, oscillation amplitude, metal level in crystallizer, and position of industrial bucket stopper. Results. The problem was formulated and key parameters were determined, which are taken into account in system’s algorithm, which made it possible to develop control system for continuous casting plant to solve problem of improving quality of resulting billet. Conclusions. A parametric model and generalized black box model representation were created, which are necessary for both new continuous casting projects and existing units to optimize metal casting process. To set up continuous casting system, controlled parameters such as pouring speed, oscillation frequency and amplitude, metal level in crystallizer, and position of industrial bucket stopper were determined. The algorithm of control system for continuous casting plant was developed, on basis of which system was developed that allows monitoring, regulation and control of obtaining steel process or non-ferrous billets. The developed user interface of control system is simple and easy to use.