Nucor Corporation

Robert Nooning, Jr

Harold Bradley Rees

Jeffery Edward Keffer

Walter N Blejde

Mark Schlichting

Gary McQuillis

Neera Jain Sundaram

Alan J Deno

Wilhelm Schmitz

George T C Chiu

Neal Ross

Dhiren Panda

Jianqi Ruan

Roland Sellger

Ivan David Parkes

Leigh Woolley

Ulrich Albrecht-Frueh

A twin roll casting system includes a pair of counter-rotating casting rolls, a casting roll controller is configured to receive a plant input comprising at least one process control setpoint for the casting rolls. A cast strip sensor measures at least one parameter of the cast strip. A feedback controller receives measurement signals from the cast strip sensor. The feedback controller is a data-driven model including a database of state-input pairs; and executes the following steps at each time step: measure a state-input similarity between a new state observation and samples, assign a weight to each consequent output of samples based on the measured state input similarity, and sum the weighted outputs and predict an output of a new state observation. The feedback controller is configured to provide the control setpoint to the casting roll controller based on the predicted output of the new state observation.

Training-free data-driven method for input-output modeling of complex process

An apparatus for continuously casting thin strip has a pair of internally cooled counter-rotatable casting rolls having casting surfaces, the pair of casting rolls laterally positioned to form a gap at a nip between the casting rolls through which a thin metal strip can be cast, where the casting surface of each casting roll has a roll profile extending in an axial direction of the corresponding casting roll; a metal delivery system adapted to deliver molten metal above the nip to form a casting pool; and a temperature altering source external to the casting roll and having one or more zones configured to alter the casting roll profile of at least one of the pair of casting rolls by locally heating or cooling the casting roll.

Method for altering casting roll profile with the alteration of localized temperature

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.

Method for casting metal strip with edge control

Methods 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, and 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, and 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.

A metal delivery nozzle for a twin roll caster adapted to extend along and above a pair of casting rolls has a main portion with one or two refractory pieces with outlets adapted to deliver molten metal to a casting pool supported by the casting rolls during casting; refractory delivery end portions separately supported adapted to move relative to the main portion at each end portion of the metal delivery nozzle, each refractory delivery end portion having a reservoir portion with passages there through adapted to deliver molten metal to the casting pool adjacent the side dams and the end portions of the casting rolls; and a mechanism connected to each refractory delivery end portion adapted to move said refractory delivery end portion relative to the main portion as casting proceeds to maintain desired distance between the refractory delivery end portions and the side dams.

Multiple pieces core nozzle

A method of continuously casting metal strip having the steps of assembling a pair of counter-rotatable casting rolls, assembling a metal delivery system adapted to deliver molten metal above the nip to form a casting pool, the casting pool forming a meniscus with each casting surface of the casting rolls, delivering a shell thickness controlling gas to select areas within 300 mm of end portions of at least one casting roll downwardly toward the meniscus between the casting pool and the casting surface adapted to control thickness of the metal shell, and control attenuation of the casting roll, and sensing the temperature and thickness profiles of the cast strip downstream from the nip to determine high or low temperature areas of the cast strip within 300 mm of the end portions and causing the gas to be delivered to the high or low temperature areas to change the thickness of the metal shell.

Growing community of inventors

Zionsville, IN, United States of America

Robert Nooning, Jr