Sensing events in a metal casting system

Abstract

Systems and methods are disclosed for an event detection system that captures data associated with events while a DC casting system forms an ingot, determines characteristics of the events, and improves the casting system based on the events. Example systems and methods may include initiating a casting operation using one or more pieces of equipment of a casting system including a casting apparatus; capturing sensor data associated with one or more acoustic signals captured relative to the one or more pieces of equipment performing the casting operation; comparing the sensor data with a set of acoustic profiles; determining whether a particular type of event has occurred; causing an adjustment to the casting system or to the casting operation based on whether the particular type of event has occurred; and initiating a second casting operation using the adjusted casting system or casting operation.

That which is claimed is: 
     
         1 . A non-transitory computer readable medium comprising program code, which when executed by a processor, is configured to cause the processor to:
 receive sensor data from a sensor about a direct chill casting operation;   compare the sensor data with reference data; and   generate a modified casting recipe for the direct chill casting operation.   
     
     
         2 . The non-transitory computer readable medium of  claim 1 , wherein the sensor is an acoustic sensor and wherein the sensor data comprises acoustic signals. 
     
     
         3 . The non-transitory computer readable medium of  claim 2 , wherein the program code, which when executed by a processor is configured to further generate a set of acoustic profiles using the sensor data. 
     
     
         4 . The non-transitory computer readable medium of  claim 1 , wherein the program code, which when executed by a processor is configured to further determine whether a particular type of event has occurred. 
     
     
         5 . The non-transitory computer readable medium of  claim 4 , wherein the program code, which when executed by a processor is configured to further determine a recommendation regarding whether the particular type of event has occurred and a likelihood that the particular type of event has occurred based on the sensor data. 
     
     
         6 . The non-transitory computer readable medium of  claim 4 , wherein the particular type of event includes one or more of a bleed out, a bleed over, a butt bounce, butt curl, or a water cooling operation. 
     
     
         7 . The non-transitory computer readable medium of  claim 1 , wherein the program code, which when executed by a processor is configured to further cause shutting off a casting apparatus. 
     
     
         8 . The non-transitory computer readable medium of  claim 1 , wherein the program code, which when executed by a processor is configured to further control one or more pieces of equipment of the direct chill casting operation pursuant to the modified casting recipe. 
     
     
         9 . A system for detecting events during a direct chill casting operation, the system comprising:
 at least one processor; and   at least one sensor configured to capture sensor data associated with a casting operation, wherein the at least one sensor is operably connected to the at least one processor, and wherein the at least one processor is configured to:   receive the sensor data from a sensor about a direct chill casting operation;   compare the sensor data with reference data; and   generating a modified casting recipe for the direct chill casting operation.   
     
     
         10 . The system of  claim 9 , wherein the at least one sensor comprises an acoustic sensor and the acoustic sensor is configured to capture initial sensor data associated with acoustic signals from multiple casting operations over an initial period of time, and
 wherein the at least one processor is further configured to:
 generate, using the initial acoustic signals, a set of acoustic profiles, each acoustic profile of the set of acoustic profiles being associated with a type of event associated with the multiple casting operations over the initial period of time. 
   
     
     
         11 . The system of  claim 10 , wherein the at least one processor is further configured to update the set of acoustic profiles using the sensor data and a determination of whether a particular type of event has occurred. 
     
     
         12 . The system of  claim 10 , wherein a characteristics of the acoustic signals include one or more of frequency, pitch, loudness, or tone. 
     
     
         13 . The system of  claim 9 , wherein the at least one processor is further configured to determine a recommendation regarding whether a particular type of event has occurred and a likelihood that the particular type of event has occurred based on the sensor data. 
     
     
         14 . The system of  claim 13 , wherein the particular type of event includes one or more of a bleed out, a bleed over, a butt bounce, butt curl, or a water cooling operation. 
     
     
         15 . The system of  claim 9 , further comprising a melting furnace, a holding furnace and a degasser. 
     
     
         16 . The system of  claim 9 , further comprising one or more pieces of equipment of a casting system, wherein the at least one processor is further configured to control the one or more pieces of equipment of the casting system pursuant to the modified casting recipe. 
     
     
         17 . A method of controlling a direct chill casting operation, the method comprising:
 receiving, by a controller, sensor data from a sensor about the direct chill casting operation;   comparing, by the controller, the sensor data with reference data; and   generating, by the controller, a modified casting recipe for the direct chill casting operation.   
     
     
         18 . The method of  claim 17 , further comprising shutting off a casting apparatus. 
     
     
         19 . The method of  claim 17 , wherein the sensor data comprises acoustic signals. 
     
     
         20 . The method of  claim 17 , further comprising determining whether a particular type of event has occurred based on the sensor data.