This paper is focused on computer aided technological processes of continuous steel casting devices. The paper characterized the fundamental aspects of creating computer aided control process of continuous steel casting operations. There is in detail described software system AMKO (Algorithm Modelling conicities). The importance of software AMKO consists in extending the usability of copper enclosure in the case of its weariness and the possibility of its further use. Using this software to create graphical model of the wear, which shows the conicity of the studied mold along all its lengths and specifies the possibility of its further use in various compositions sequences. Such modelling and prediction is possible with usage of cybernetic modelling principles and methods known as soft-computing

J. David

P. Švec

R. Frischer

R. Garzinova

English

Hrčak - Portal of scientific journals of Croatia

193METALURGIJA 53 (2014) 2, 193-196J. DAVID, P. ŠVEC, R. FRISCHER, R. GARZINOVÁTHE COMPUTER SUPPORT OF DIAGNOSTICS OF CIRCLE CRYSTALLIZERSReceived – Prispjelo: 2013-06-21Accepted – Prihvaćeno: 2013-10-30Preliminary Note – Prethodno priopćenjeISSN 0543-5846METABK 53(2) 193-196 (2014)UDC – UDK 669.14.018:620.17:004.032:608.4=111J. David, R. Frischer, P. Švec, R. Garzinová, Faculty of Metallurgy and Material Engineering, VŠB – Technical University of Ostrava, Czech RepublicThis paper is f ocused on c omputer aided t echnological processes of c ontinuous steel casting devic es. The paper characterized the fundamental aspects of creating computer aided control process of continuous steel casting op-erations. There is in detail described sof tware system AMKO (Algorithm Modelling conicities). The impor tance of software AMKO consists in extending the usability of copper enclosure in the case of its weariness and the possibil-ity of its fur ther use. Using this sof tware to create graphical model of the w ear, which sho ws the c onicity of the studied mold along all its lengths and speciĀ es the possibility of its further use in various compositions sequences. Such modelling and pr ediction is possible with usage of c ybernetic modelling principles and methods k nown as soft-computing. Key words: crystallizers, diagnostics, computer support, software, conicityINTRODUCTIONIncreasing complexity of production devices and in-creasing demands to productivity and production qual-ity demand the need of high reliability of devices and effi cient control of maintenance actions with usage of systems of reliability and maintenance control. Mainte-nance control systems providing needed support for planning and controlling all of the actions interconnect-ed with device maintenance from its installation until preventative or operative servicing. Contributions when introducing these systems can be found in improvement of decision making processes, when the system consid-erably oversimplify providing of the base information for planning of maintenance actions and evaluation of economical indexes. Cohesion of these system to sys-tem of acquisition of process data and technological data seems to be very good when monitoring and diag-nose the state of production device and in determination of time, proper form maintenance when it is suffi ciently confi dent about origin of limiting value of wear respec-tively predictive time to limiting  value  can  origin.  Consequential on  monitoring of operational data and planning preventive maintenance with emphasis on op-timization of the work and lowering time delays will bring effi cient usage of the sources.Reliability and maintenance control systems gives us an analysis of the maintenance actions, failure analy-sis, costs analysis spent to made actions and spare parts. It gives the answers to questions, which would be with-out a complex look over the data derived hardly – if the given crystallizer’s desks can be used in operation or if is necessary to make its renovation. On history basis of previously actions or another historical data the mainte-nance control system gives suffi  cient information for correct decision make. Thanks to recently made mainte-nance data collection the base for maintenance planning is improving. Introduction of reliability control system and maintenance further help to increase availability and serviceability of devices from the reason of lower -ing unplanned time delays, breakdowns and increase device’s service life [1].The system should give information about planning device revisions and about their state with the estima-tion of costs to planned revisions and preventive main-tenance, but also help with better organization of work, increasing the share of planned maintenance in conse-quence to lowering idle times of maintenance mans and volume of overtime work.From above mentioned result, that presumption from making an effective reliability control system and main-tenance ensure working with longer time horizon is crea-tion of feedback. Feedback function [2] can fulfi ll system for data acquisition which provides information for regu-lation of impacts on reliability in all phases of lifetime  cycle, which is complete with diagnostic system. The system has to enable access to stored data about reliabil-ity, to ef fective statistical prediction, other quantitative  and qualitative methods and to models suitable for pre-diction, analysis and estimations of reliability indicators.DEVELOPMENT OF MONITORING AND INFORMATION SYSTEMIn terms of scientifi c research activities, the issues of development of new progressive tools and reliability 194  METALURGIJA 53 (2014) 2, 193-196J. DAVID et al.: THE COMPUTER SUPPORT OF DIAGNOSTICS OF CIRCLE CRYSTALLIZERScontrol support systems for primary cooling on continu-ous casting devices for quality improvement of exacting fl at products is making monitoring and information sys-tem of reliability and maintenance controlling, whose target isn’t pure gathering of operational data and infor-mation, statistical estimation of given reliability indica-tors, but also usage of results for reliability control and resulting maintenance control. Modern system concep-tion has to be equipped following basic stages, which making integral unit:•  Defi nition of the system and assessments on the object control system,•  Analysis of the system and defi  nition of the sys-tem’s state,•  Option of methods type and progress to reach the goals placed of device’s system,•  Elaboration of scheme of information acquisition from operation advanced into unique way of ex-pression and description,•  Elaboration of mathematic – statistic methods for processing of gathered data,•  Elaboration of corresponding mathematical mod-els for calculation of the object characteristics,•  Making an analysis of results and applying techno-logical changes in production and in operation ac-cording this analysis.Regarding to above mentioned factors is important, to the reliability and maintenance control system be able to realize concept of maintenance according to real state beside the concept of preventive maintenance. Ba-sic philosophy of solution preparation and implementa-tion of maintenance processes when realization of maintenance conception according to the real state comes out from the demand of preservation of produc-tion device in operational and dispensable state.Main system function should be: •  Trace actual state of each crystallizer’s desks from the point of it’s wear and position in technological operational cycle and maintenance in real time,•  Record and evaluate running of technological and operational quantities, which has infl uence to crys-tallizer’s desk wear,•  Trace and record each maintenance actions,•  Trace operation cycles and crystallizer ’s desk maintenance in relation to blanks quality,•  Quantifi cation of reliability and economic indica-tors of crystallizer’s desks,•  Ensure interconnection with diagnostic system and visualization of it results in on-lie and of f-line mode,•  Visualize history of operation and maintenance ac-tions on each crystallizer’s desks,•  Ensure integrated supervisor control in technical life of crystallizer’s desks process,•  Ensure immediate availability detail production reports and data from production.SYSTEM FOR DETERMININGCRYSTALLIZER’S CONICITY One of the computer systems for management support in continuous casting systems is the system for determin-ing crystallizer´s conicity. Importance of this system arises from technological importance of this parameter. In the ingot molds is required dimensional stability , wear resistance and high thermal conductivity . Ingot mold is exposed to extreme cyclical, thermal and me-chanical stress.In ingot mold is a high temperature dif ference be-tween the outer and inner surface, which is due to the high density of heat fl ow. This generates thermal stress and plastic deformation, which is undesirable from the operational point of view. Crystallizers are basically re-moved because of two reasons, due to loss of taper wear, and also due to permanent deformation of the walls of ingot mold. The lar gest deformation is on the liquid steel surface and just below it. (Figure 1)Experimental research of crystallizer is complex task because of the high temperatures and the danger arising from the presence of the molten liquid steel near the cooling water . Structural adjustment of the device before experiments are costly and may delay the pro-duction. Experimental research must always take a place in conjunction with the production company workplace, which must conform to the priorities of pro-duction. In addition to experimental research has an ir -replaceable position also mathematical modeling (for example fi nite element method, and so on) [3].The material for the production of crystallizers is a copper, usually alloyed by small amounts of additives in particular for increasing the surface hardness and wear resistance. At the same time is also achieved in-creased of the recrystallization temperature. In particu-lar, the alloying elements are P, Ag, Cr, Zr, Co and Be.Alloying:•  Slows down the walls wear due to abrasive effects of casting and casting bark powder , increases  re-Figure 1 Crystallizer’s wear195METALURGIJA 53 (2014) 2, 193-196J. DAVID et al.: THE COMPUTER SUPPORT OF DIAGNOSTICS OF CIRCLE CRYSTALLIZERSheat engineering, materials engineering, experimental methods and numerical methods.As mentioned above, the technical and fi nancial re-quirements of diameter measurement crystallizer in practice (Figure 2), arise requirement to develop soft-ware that would allow to simulate the real environment and whose output is the state of the crystallizer after a specifi ed number of cast steel melts of different brands.Using the principles and methods of cyberspace (functional) simulation model [4, 5], that uses the so-called “black box”, was created software AMKO (Al-gorithm Modelling conicities) allow the determination of the diameter of the crystallizer on 18 levels along the height of the crystallizer , which is subsequently deter -mined the resulting crystallizer’s conicity.On Figure 3 is presented basic screen of created software product AMKO.The input section is composed of 120 inputs. Inputs 01-100 represent the count of steel grades, as well as the input data is value total weight of cast melts, their number and the initial dimensions of the crystallizer one the individual levels.The output part represent the right half part of the screen with a graphic profi le of the crystallizer and the calculated values of the average levels of crystallizer from which are subsequently determined the crystallizer conicity value. [6]CONCLUSIONEach steel grade is characterized by its chemical composition having different characteristics that signif-icantly affect the life of the crystallizer. Suitable choice of casting steel grades and their casting sequence can be achieved its lifetime extending.The importance of software AMKO consists in ex-tending the usability of copper enclosure in the case of its weariness and the possibility of its further use. Using this software to create graphical model of the wear , which  Figure 2  Measuring of crystallizer enclosure by MKL  100/420 systemcrystallization temperature, increases elastic mod-ulus, yield strength and tensile strength of the ma-terial, extends the life of the crystallizer´s  inserts.•  Reduces thermal conductivity.  Infl uence of alloy-ing elements on the thermal expansion coeffi cient of the material is minimal.From the above it follows that the problem solution of crystallizer’s walls plastic deformation is not only in the choice of plate material. The technical solution is very exacting interdisciplinary problem that involves discipline of structure, strength and elasticity-plasticity, Figure 3 Basic screen of system AMKO196  METALURGIJA 53 (2014) 2, 193-196J. DAVID et al.: THE COMPUTER SUPPORT OF DIAGNOSTICS OF CIRCLE CRYSTALLIZERSshows the conicity of the studied mold along all its lengths and specifi es the possibility of its further use in various  compositions sequences. Such modelling and prediction  is possible with usage of cybernetic modeling principles  (functional) and methods known as soft-computing.Developed software will be used for the simulation and experimentation with the mold behavior in continu-ous steel casting devices and prediction its condition. AcknowledgementsThis publication paper originated thanks to fi nancial aid of Ministry of Industry and Trade of the Czech Re-public grant-project solution, TIP registration number FR-TI3/374.REFERENCES [1] J. David, M. Heger, M. Vrozina et al  Visualisation of Data Fields. Archives of Metallurgy And Materials. 55 (2010) 3, 795-801.[2] Z. Jančíková, V. Roubíček, D. Juchelková, D. Application of Artifi cial Intelligence Methods for Prediction of Steel Mechanical Properties. Metalur gija. 47 (2008) 4, 339-342. [3] Z. Jančíková, O. Zimný, P. Koštial Prediction of metal cor-rosion by neural network. Metalur gija. 52 (2013) 3 379-381.[4] Z. Gorny , S. Kluska-Nawarecka,D. Wilk-Kolodziejczyk Attribute-Based Knowledge Representation in the Process of Defect Diagnosis.. Archives of Metallur gy And Mate-rials.  55 (2010) 3, 819-826.[5] Z. Górny, S. Kluska-Nawarecka, D. Wilk-Kołodziejczyk, K. Regulski Diagnosis of Casting Defects Using Uncertain and Incomplete Knowledge. Archives of Metallur gy and Materials. 55 (2010) 3, 827-836. [6] J. David, P . Švec, R. Frischer Modelling of crystallizer wear. Archives of Materials Science and Engineering. 58 (2012) 2, 193-198.Note:  The responsible person for English language is the lecturer from TU Ostrava

The computer support of diagnostics of circle crystallizers

This paper is focused on computer aided technological processes of continuous steel casting devices. The paper
characterized the fundamental aspects of creating computer aided control process of continuous steel casting operations.
There is in detail described software system AMKO (Algorithm Modelling conicities). The importance of
software AMKO consists in extending the usability of copper enclosure in the case of its weariness and the possibility
of its further use. Using this software to create graphical model of the wear, which shows the conicity of the
studied mold along all its lengths and speciĀ es the possibility of its further use in various compositions sequences.
Such modelling and prediction is possible with usage of cybernetic modelling principles and methods known as
soft-computing.Web of Science53219619

David, Jiří

Švec, Pavel

Frischer, Robert

Garzinová, Romana

DSpace at VSB Technical University of Ostrava

193METALURGIJA 53 (2014) 2, 193-196J. DAVID, P. ŠVEC, R. FRISCHER, R. GARZINOVÁTHE COMPUTER SUPPORT OF DIAGNOSTICS OF CIRCLE CRYSTALLIZERSReceived – Prispjelo: 2013-06-21Accepted – Prihvaćeno: 2013-10-30Preliminary Note – Prethodno priopćenjeISSN 0543-5846METABK 53(2) 193-196 (2014)UDC – UDK 669.14.018:620.17:004.032:608.4=111J. David, R. Frischer, P. Švec, R. Garzinová, Faculty of Metallurgy and Material Engineering, VŠB – Technical University of Ostrava, Czech RepublicThis paper is f ocused on c omputer aided t echnological processes of c ontinuous steel casting devic es. The paper characterized the fundamental aspects of creating computer aided control process of continuous steel casting op-erations. There is in detail described sof tware system AMKO (Algorithm Modelling conicities). The impor tance of software AMKO consists in extending the usability of copper enclosure in the case of its weariness and the possibil-ity of its fur ther use. Using this sof tware to create graphical model of the w ear, which sho ws the c onicity of the studied mold along all its lengths and speciĀ es the possibility of its further use in various compositions sequences. Such modelling and pr ediction is possible with usage of c ybernetic modelling principles and methods k nown as soft-computing. Key words: crystallizers, diagnostics, computer support, software, conicityINTRODUCTIONIncreasing complexity of production devices and in-creasing demands to productivity and production qual-ity demand the need of high reliability of devices and efﬁ cient control of maintenance actions with usage of systems of reliability and maintenance control. Mainte-nance control systems providing needed support for planning and controlling all of the actions interconnect-ed with device maintenance from its installation until preventative or operative servicing. Contributions when introducing these systems can be found in improvement of decision making processes, when the system consid-erably oversimplify providing of the base information for planning of maintenance actions and evaluation of economical indexes. Cohesion of these system to sys-tem of acquisition of process data and technological data seems to be very good when monitoring and diag-nose the state of production device and in determination of time, proper form maintenance when it is sufﬁ ciently conﬁ dent about origin of limiting value of wear respec-tively predictive time to limiting  value  can  origin.  Consequential on  monitoring of operational data and planning preventive maintenance with emphasis on op-timization of the work and lowering time delays will bring efﬁ cient usage of the sources.Reliability and maintenance control systems gives us an analysis of the maintenance actions, failure analy-sis, costs analysis spent to made actions and spare parts. It gives the answers to questions, which would be with-out a complex look over the data derived hardly – if the given crystallizer’s desks can be used in operation or if is necessary to make its renovation. On history basis of previously actions or another historical data the mainte-nance control system gives sufﬁ  cient information for correct decision make. Thanks to recently made mainte-nance data collection the base for maintenance planning is improving. Introduction of reliability control system and maintenance further help to increase availability and serviceability of devices from the reason of lower -ing unplanned time delays, breakdowns and increase device’s service life [1].The system should give information about planning device revisions and about their state with the estima-tion of costs to planned revisions and preventive main-tenance, but also help with better organization of work, increasing the share of planned maintenance in conse-quence to lowering idle times of maintenance mans and volume of overtime work.From above mentioned result, that presumption from making an effective reliability control system and main-tenance ensure working with longer time horizon is crea-tion of feedback. Feedback function [2] can fulﬁ ll system for data acquisition which provides information for regu-lation of impacts on reliability in all phases of lifetime  cycle, which is complete with diagnostic system. The system has to enable access to stored data about reliabil-ity, to ef fective statistical prediction, other quantitative  and qualitative methods and to models suitable for pre-diction, analysis and estimations of reliability indicators.DEVELOPMENT OF MONITORING AND INFORMATION SYSTEMIn terms of scientiﬁ c research activities, the issues of development of new progressive tools and reliability 194  METALURGIJA 53 (2014) 2, 193-196J. DAVID et al.: THE COMPUTER SUPPORT OF DIAGNOSTICS OF CIRCLE CRYSTALLIZERScontrol support systems for primary cooling on continu-ous casting devices for quality improvement of exacting ﬂ at products is making monitoring and information sys-tem of reliability and maintenance controlling, whose target isn’t pure gathering of operational data and infor-mation, statistical estimation of given reliability indica-tors, but also usage of results for reliability control and resulting maintenance control. Modern system concep-tion has to be equipped following basic stages, which making integral unit:•  Deﬁ nition of the system and assessments on the object control system,•  Analysis of the system and deﬁ  nition of the sys-tem’s state,•  Option of methods type and progress to reach the goals placed of device’s system,•  Elaboration of scheme of information acquisition from operation advanced into unique way of ex-pression and description,•  Elaboration of mathematic – statistic methods for processing of gathered data,•  Elaboration of corresponding mathematical mod-els for calculation of the object characteristics,•  Making an analysis of results and applying techno-logical changes in production and in operation ac-cording this analysis.Regarding to above mentioned factors is important, to the reliability and maintenance control system be able to realize concept of maintenance according to real state beside the concept of preventive maintenance. Ba-sic philosophy of solution preparation and implementa-tion of maintenance processes when realization of maintenance conception according to the real state comes out from the demand of preservation of produc-tion device in operational and dispensable state.Main system function should be: •  Trace actual state of each crystallizer’s desks from the point of it’s wear and position in technological operational cycle and maintenance in real time,•  Record and evaluate running of technological and operational quantities, which has inﬂ uence to crys-tallizer’s desk wear,•  Trace and record each maintenance actions,•  Trace operation cycles and crystallizer ’s desk maintenance in relation to blanks quality,•  Quantiﬁ cation of reliability and economic indica-tors of crystallizer’s desks,•  Ensure interconnection with diagnostic system and visualization of it results in on-lie and of f-line mode,•  Visualize history of operation and maintenance ac-tions on each crystallizer’s desks,•  Ensure integrated supervisor control in technical life of crystallizer’s desks process,•  Ensure immediate availability detail production reports and data from production.SYSTEM FOR DETERMININGCRYSTALLIZER’S CONICITY One of the computer systems for management support in continuous casting systems is the system for determin-ing crystallizer´s conicity. Importance of this system arises from technological importance of this parameter. In the ingot molds is required dimensional stability , wear resistance and high thermal conductivity . Ingot mold is exposed to extreme cyclical, thermal and me-chanical stress.In ingot mold is a high temperature dif ference be-tween the outer and inner surface, which is due to the high density of heat ﬂ ow. This generates thermal stress and plastic deformation, which is undesirable from the operational point of view. Crystallizers are basically re-moved because of two reasons, due to loss of taper wear, and also due to permanent deformation of the walls of ingot mold. The lar gest deformation is on the liquid steel surface and just below it. (Figure 1)Experimental research of crystallizer is complex task because of the high temperatures and the danger arising from the presence of the molten liquid steel near the cooling water . Structural adjustment of the device before experiments are costly and may delay the pro-duction. Experimental research must always take a place in conjunction with the production company workplace, which must conform to the priorities of pro-duction. In addition to experimental research has an ir -replaceable position also mathematical modeling (for example ﬁ nite element method, and so on) [3].The material for the production of crystallizers is a copper, usually alloyed by small amounts of additives in particular for increasing the surface hardness and wear resistance. At the same time is also achieved in-creased of the recrystallization temperature. In particu-lar, the alloying elements are P, Ag, Cr, Zr, Co and Be.Alloying:•  Slows down the walls wear due to abrasive effects of casting and casting bark powder , increases  re-Figure 1 Crystallizer’s wear195METALURGIJA 53 (2014) 2, 193-196J. DAVID et al.: THE COMPUTER SUPPORT OF DIAGNOSTICS OF CIRCLE CRYSTALLIZERSheat engineering, materials engineering, experimental methods and numerical methods.As mentioned above, the technical and ﬁ nancial re-quirements of diameter measurement crystallizer in practice (Figure 2), arise requirement to develop soft-ware that would allow to simulate the real environment and whose output is the state of the crystallizer after a speciﬁ ed number of cast steel melts of different brands.Using the principles and methods of cyberspace (functional) simulation model [4, 5], that uses the so-called “black box”, was created software AMKO (Al-gorithm Modelling conicities) allow the determination of the diameter of the crystallizer on 18 levels along the height of the crystallizer , which is subsequently deter -mined the resulting crystallizer’s conicity.On Figure 3 is presented basic screen of created software product AMKO.The input section is composed of 120 inputs. Inputs 01-100 represent the count of steel grades, as well as the input data is value total weight of cast melts, their number and the initial dimensions of the crystallizer one the individual levels.The output part represent the right half part of the screen with a graphic proﬁ le of the crystallizer and the calculated values of the average levels of crystallizer from which are subsequently determined the crystallizer conicity value. [6]CONCLUSIONEach steel grade is characterized by its chemical composition having different characteristics that signif-icantly affect the life of the crystallizer. Suitable choice of casting steel grades and their casting sequence can be achieved its lifetime extending.The importance of software AMKO consists in ex-tending the usability of copper enclosure in the case of its weariness and the possibility of its further use. Using this software to create graphical model of the wear , which  Figure 2  Measuring of crystallizer enclosure by MKL  100/420 systemcrystallization temperature, increases elastic mod-ulus, yield strength and tensile strength of the ma-terial, extends the life of the crystallizer´s  inserts.•  Reduces thermal conductivity.  Inﬂ uence of alloy-ing elements on the thermal expansion coefﬁ cient of the material is minimal.From the above it follows that the problem solution of crystallizer’s walls plastic deformation is not only in the choice of plate material. The technical solution is very exacting interdisciplinary problem that involves discipline of structure, strength and elasticity-plasticity, Figure 3 Basic screen of system AMKO196  METALURGIJA 53 (2014) 2, 193-196J. DAVID et al.: THE COMPUTER SUPPORT OF DIAGNOSTICS OF CIRCLE CRYSTALLIZERSshows the conicity of the studied mold along all its lengths and speciﬁ es the possibility of its further use in various  compositions sequences. Such modelling and prediction  is possible with usage of cybernetic modeling principles  (functional) and methods known as soft-computing.Developed software will be used for the simulation and experimentation with the mold behavior in continu-ous steel casting devices and prediction its condition. AcknowledgementsThis publication paper originated thanks to ﬁ nancial aid of Ministry of Industry and Trade of the Czech Re-public grant-project solution, TIP registration number FR-TI3/374.REFERENCES [1] J. David, M. Heger, M. Vrozina et al  Visualisation of Data Fields. Archives of Metallurgy And Materials. 55 (2010) 3, 795-801.[2] Z. Jančíková, V. Roubíček, D. Juchelková, D. Application of Artiﬁ cial Intelligence Methods for Prediction of Steel Mechanical Properties. Metalur gija. 47 (2008) 4, 339-342. [3] Z. Jančíková, O. Zimný, P. Koštial Prediction of metal cor-rosion by neural network. Metalur gija. 52 (2013) 3 379-381.[4] Z. Gorny , S. Kluska-Nawarecka,D. Wilk-Kolodziejczyk Attribute-Based Knowledge Representation in the Process of Defect Diagnosis.. Archives of Metallur gy And Mate-rials.  55 (2010) 3, 819-826.[5] Z. Górny, S. Kluska-Nawarecka, D. Wilk-Kołodziejczyk, K. Regulski Diagnosis of Casting Defects Using Uncertain and Incomplete Knowledge. Archives of Metallur gy and Materials. 55 (2010) 3, 827-836. [6] J. David, P . Švec, R. Frischer Modelling of crystallizer wear. Archives of Materials Science and Engineering. 58 (2012) 2, 193-198.Note:  The responsible person for English language is the lecturer from TU Ostrava

Directory of Open Access Journals

http://doaj.org/search?source=%7B%22query%22%3A%7B%22bool%22%3A%7B%22must%22%3A%5B%7B%22term%22%3A%7B%22id%22%3A%227055fa0ced3f427dba58caa178246eb2%22%7D%7D%5D%7D%7D%7D

The computer support of diagnostics of circle crystallizers

Abstract

Similar works

Full text

Available Versions

Hrčak - Portal of scientific journals of Croatia

DSpace at VSB Technical University of Ostrava

Directory of Open Access Journals